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125E-5 Series
125E-5 Series 1
SEN00179-16 00 Index and foreword
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00177-16
01 Specification.................................................................................................................... SEN00181-07
Specification and technical data...................................................................................... SEN00182-07 q
2 125E-5 Series
00 Index and foreword SEN00179-16
Table of contents 1
00 Index and foreword
Index ............................................................................................................................... SEN00179-16
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information.................................................................................. SEN00180-06
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data ..................................................................................... SEN00182-07
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 21
Weight table............................................................................................................................. 48
Engine performance curves..................................................................................................... 51
125E-5 Series 3
SEN00179-16 00 Index and foreword
4 125E-5 Series
00 Index and foreword SEN00179-16
40 Troubleshooting
General information on troubleshooting.......................................................................... SEN00548-03
General information on troubleshooting ...................................................................................... 2
Points on troubleshooting ........................................................................................................ 2
Error code and failure code table ............................................................................................ 4
Information in troubleshooting table ........................................................................................ 8
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00550-01
Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure................................................................ 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 6
E-3 Code [122/CA122] Charge Air Press Sensor High Error .................................................. 8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error ................................................... 10
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 12
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 16
E-7 Code [135/CA135] Oil press. Sensor High Error .............................................................. 18
E-8 Code [141/CA141] Oil press. Sensor Low Error ............................................................... 20
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 22
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 24
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error ................................................ 26
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ................................................ 28
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 29
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error.............................................. 30
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 32
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 34
E-17 Code [234/CA234] Eng. Overspeed ............................................................................... 36
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error.................................................... 38
E-19 Code [263/CA263] Fuel Temp. Sensor High Error.......................................................... 40
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 42
E-21 Code [271/CA271] PCV1 Short Error ............................................................................. 44
E-22 Code [272/CA272] PCV1 Open Error ............................................................................. 46
E-23 Code [273/CA273] PCV2 Short Error ............................................................................. 48
E-24 Code [274/CA274] PCV2 Open Error ............................................................................. 50
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ................................. 52
E-26 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error ................................. 54
E-27 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error ................................. 56
E-28 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error ................................. 58
E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error ................................. 60
E-30 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error ................................. 62
E-31 Code [342/CA342] Calibration Code Incompatibility ....................................................... 64
E-32 Code [351/CA351] INJ. Drive Circuit Error ..................................................................... 66
125E-5 Series 5
SEN00179-16 00 Index and foreword
6 125E-5 Series
00 Index and foreword SEN00179-16
125E-5 Series 7
SEN00179-16
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
8
SEN00180-06
125E-5 Series
125E-5 Series 1
SEN00180-06 00 Index and foreword
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 125E-5 Series
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125E-5 Series 3
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4 125E-5 Series
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q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
125E-5 Series 5
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8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 125E-5 Series
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q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
125E-5 Series 7
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3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 125E-5 Series
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Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
125E-5 Series 9
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10 125E-5 Series
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125E-5 Series 11
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 125E-5 Series
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125E-5 Series 13
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2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 125E-5 Series
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3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
125E-5 Series 15
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16 125E-5 Series
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
125E-5 Series 17
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3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 125E-5 Series
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6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
125E-5 Series 19
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20 125E-5 Series
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q 114 engine
q 107 engine
125E-5 Series 21
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q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 125E-5 Series
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
125E-5 Series 23
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2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 125E-5 Series
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(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
125E-5 Series 25
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3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 125E-5 Series
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a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
125E-5 Series 27
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28 125E-5 Series
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Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
125E-5 Series 29
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Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 125E-5 Series
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Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
125E-5 Series 31
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a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 125E-5 Series
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125E-5 Series 33
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5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 125E-5 Series
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8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
125E-5 Series 35
SEN00180-06 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 125E-5 Series
00 Index and foreword SEN00180-06
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
125E-5 Series 37
SEN00180-06 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 125E-5 Series
00 Index and foreword SEN00180-06
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
125E-5 Series 39
SEN00180-06 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 125E-5 Series
00 Index and foreword SEN00180-06
125E-5 Series 41
SEN00180-06
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
42
SEN00182-07
125E-5 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 6
General view ...................................................................................................................................... 20
Weight table ....................................................................................................................................... 48
Engine performance curves ............................................................................................................... 51
125E-5 Series 1
SEN00182-07 01 Specification
Outline 1
1. Applicable machine
2 125E-5 Series
01 Specification SEN00182-07
q The 125E-5 engine is a high-performance and 5) The common rail high-pressure fuel injection
high-efficiency engine, which passed strict system controlled electronically is employed
emission regulations (USA: EPA Regulations for the 125E-3 and after models. This system
for 2006, EU: Regulations for 2006, Japan: can inject the fuel at high pressure of 120 MPa
Construction machinery regulations for 2006) {1,200 kg/cm2} from the low-speed range to the
and attained low fuel consumption, low noise, high-speed range. In addition, this system can
better exhaust gas color, and high acceleration control the form of injection most properly by
performance. Accordingly, this newly devel- electronic control according to the speed and
oped engine is suitable as a power source of load. The injection system of 125E-5 is further
construction machinery and industrial machin- improved to employ multiple injection and
ery used for various purposes. increase the injection pressure up to 140 MPa
{1,400 kg/cm2}. As a result, exhaust gas of the
q The 125E-5 engine is the successor to the cleanest level in the world, good exhaust gas
125E-3 engine. While it is an in-line 6-cylinder, color, low fuel consumption, and low noise are
water-cooled, common rail direct injection, 4- realized simultaneously.
stroke diesel engine, it is equipped with the
cooled EGR system which is a new technol- 6) As the injection pressure of the common rail
ogy. injection system employed for the 125E-3
engine and after models is increased (from
1) The main components of the cooled EGR sys- 120 to 140 MPa {from 1,200 to 1,400 kg/cm2}),
tem are the EGR cooler of corrugated tube the pressure resistance of the common rail,
type made of newly developed special stain- injector, and supply pump is improved for
less steel and the EGR valve driven hydrauli- higher reliability.
cally and controlled electronically which
KOMATSU developed by itself. The cooled 7) The main fuel filter of high efficiency and the
EGR system secures the optimum EGR rate pre-fuel filter are installed as standard so that
from the low-speed range to the high-speed the low grade fuel in the market (equivalent to
range to attain both clean exhaust gas and low Class NAS13) can be used. In addition, the
fuel consumption with the bypass assist circuit delivery of the priming pump used to replace
consisting of the venturi system and bypass the filters is increased for higher serviceability.
valve which has the same function and struc-
ture as those of the EGR valve. 8) The high-quality piston made of cast iron which
has been employed for the 125E-2 engine and
2) The special EGR oil pump is employed to gen- after models is employed. This piston has a
erate high oil pressure (1.47 MPa {15 kg/cm2}) less coefficient of thermal expansion, a reen-
as the drive power source of the EGR valve trant combustion chamber, and a shaker cool-
driven hydraulically and controlled electroni- ing gallery. As a result, clean exhaust gas,
cally. good exhaust gas color, and low fuel consump-
tion are attained simultaneously, and high
3) The 125E-5 engine is equipped with the com- durability and reliability are also obtained.
bination filter system of high performance and
efficiency, which has been employed for the 9) By using the above-mentioned high-pressure
125E-3 engine, to meet the requirements of fuel injection system controlled electronically,
the EGR system and high-dispersion oil and the multiple injection and injection characteris-
capture large and small particles. In addition, tics are set most properly to improve the start-
the recommended sub-materials for operation ability and reduce the white exhaust smoke
(oil and fuel) are changed to improve the reli- when the temperature is low.
ability and durability of the engine.
10) Since the engine controller is mounted on the
4) Since the high-pressure fuel injection system engine and equipped with the automatic high-
controlled electronically is employed, less soot altitude compensation function, the engine can
is produced and the draining interval of the oil be operated at high altitude without replacing
is lengthened. (While the capacity of the oil the controller. As a result, the serviceability is
pan is not changed, the oil replacement inter- improved.
val of 500 hours is secured.)
125E-5 Series 3
SEN00182-07 01 Specification
4 125E-5 Series
01 Specification SEN00182-07
q The 125E-5 EGR-less engine is a high-perfor- 5) The main fuel filter of high efficiency and the
mance and high-efficiency engine, which pre-fuel filter are installed as standard so that
attained low fuel consumption, low noise, bet- the low grade fuel in the market (equivalent to
ter exhaust gas color, and high acceleration Class NAS13) can be used. In addition, the
performance. Accordingly, this newly devel- priming pump used for replacement of the fil-
oped engine is suitable as a power source of ters is electrified for high serviceability.
construction machinery and industrial machin-
ery used for various purposes. 6) The high-quality piston made of cast iron which
has been employed for the 125E-2 engine and
q The 125E-5 EGR-less engine is the successor after models is employed. This piston has a
to the 125E-3 engine, which is an in-line 6-cyl- less coefficient of thermal expansion, a reen-
inder, water-cooled, common rail direct injec- trant combustion chamber, and a shaker cool-
tion, and 4-stroke diesel engine. ing gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consump-
1) The 125E-5 EGR-less engine is equipped with tion are attained simultaneously, and high
the combination filter system of high perfor- durability and reliability are also obtained.
m a n c e a n d e ff i c i e n c y, w h i c h h a s b e e n
employed for the 125E-3 engine, to meet the 7) By using the above-mentioned high-pressure
requirements of high-dispersion oil and cap- fuel injection system controlled electronically,
ture large and small particles. In addition, the the multiple injection and injection characteris-
recommended sub-materials for operation (oil tics are set most properly to improve the start-
and fuel) are changed to improve the reliability ability and reduce the white exhaust smoke
and durability of the engine. when the temperature is low.
2) Since the high-pressure fuel injection system 8) Since the engine controller is mounted on the
controlled electronically is employed, less soot engine and equipped with the automatic high-
is produced and the draining interval of the oil altitude compensation function, the engine can
is lengthened. (While the capacity of the oil be operated at high altitude without replacing
pan is not changed, the oil replacement inter- the controller. As a result, the serviceability is
val of 500 hours is secured.) improved.
3) The common rail high-pressure fuel injection 9) The KTR90 turbocharger newly developed and
system controlled electronically is employed manufactured by KOMATSU for higher reliabil-
for the 125E-3 and after models. This system ity and higher performance is mounted. The
can inject the fuel at high pressure of 120 MPa efficiency of the blower impeller is improved
{1,200 kg/cm2} from the low-speed range to the and special manufacturing methods for higher
high-speed range. In addition, this system can strength of the material are employed to obtain
control the form of injection most properly by higher efficiency and higher pressure ratio. As
electronic control according to the speed and a result, high performance is maintained from
load. The injection system of 125E-5 is further the low-speed range to the high-speed range.
improved to employ multiple injection. As a
result, the characteristics of good exhaust gas 10) The copper sleeve at the injector mounting
color, low fuel consumption and low noise are hole of the cylinder head is eliminated.
realized simultaneously. Instead, the dry sleeve structure is employed
and the top and bottom faces of the cylinder
4) The pressure resistance of the common rail, head are connected by casting to meet the
injector, and supply pump of the common rail requirements of the high output and attain
injection system employed for the 125E-3 higher reliability.
engine and after models is improved for higher
reliability.
125E-5 Series 5
SEN00182-07 01 Specification
Specifications 1
6 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 7
SEN00182-07 01 Specification
8 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 9
SEN00182-07 01 Specification
10 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 11
SEN00182-07 01 Specification
12 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 13
SEN00182-07 01 Specification
14 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 15
SEN00182-07 01 Specification
16 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 17
SEN00182-07 01 Specification
18 125E-5 Series
01 Specification SEN00182-07
Max. torque —
{kgm/rpm}
No-load max. speed
rpm Max. 1,890
(High idle speed)
No-load min. speed
rpm 750 ± 25
(Low idle speed)
g/kW·h 218
Fuel consumption ratio at rated output
{g/HP·h} {162}
Dry weight kg 1,450
Fuel injection pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil 63
l
(Refill capacity) (63)
Quantity of coolant 53
l
(for only engine) (21)
Alternator — 24V, 35A
Starting motor — 24V, 7.5kW
Battery — 12V, 150Ah×2
Turbocharger — KOMATSU KTR90
Air compressor — —
Others — With air-cooled aftercooler
125E-5 Series 19
SEN00182-07 01 Specification
General view 1
SAA6D125E-5 (Left side of engine)
Applicable machines: PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC450-8, PC450LC-8
1. Center of crankshaft
2. Rear face of flywheel housing
20 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 21
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
22 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 23
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
24 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 25
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
26 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 27
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
28 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 29
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
30 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 31
SEN00182-07 01 Specification
1. Center of crankshaft
32 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Rear face of flywheel housing
125E-5 Series 33
SEN00182-07 01 Specification
1. Center of crankshaft
2. Center of cylinder liner
34 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
125E-5 Series 35
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
36 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 37
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
38 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 39
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
40 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 41
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
42 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Center of cylinder liner
125E-5 Series 43
SEN00182-07 01 Specification
1. Center of crankshaft
2. Rear face of flywheel housing
44 125E-5 Series
01 Specification SEN00182-07
1. Center of crankshaft
2. Rear face of flywheel housing
125E-5 Series 45
SEN00182-07 01 Specification
1. Center of crankshaft
2. Center of cylinder liner
46 125E-5 Series
01 Specification SEN00182-07
Dimensions table
Unit: mm
Dimension of each part
Engine Machine
A B C D E F G H J
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
1,713 1,741 438 — — — — 1,001 —
PC400-8, PC400LC-8
PC450-8, PC450LC-8
PC400-8R
(*1) 1,713 1,741 438 975
PC400LC-8R
PC450-8R — — — — —
PC450LC-8R (*2) 1,484 1,744 442 1,002
PC500LC-8R
D85EX-15E0, D85EX-15R
1,307 1,711 387 15 15 777 949 1,004 —
SAA6D125E-5 D85PX-15E0, D85PX-15R
WA450-6, WA470-6
WA480-6, WA470-6R 1,334 1,638 388 25 — 800 935 — —
WA480-6R
HM250-2, HM300-2 1,681 1,268 401 178 40 530 660 1,010 718
HM300-2R 1,681 1,263 401 178 40 530 660 1,010 718
BR580JG-1 1,713 1,311 453 — — — — 1,001 —
GD755-5R 1,340 1,640 390 35 — 800 984 — —
DCA-300SSK4
1,753 1,420 371 160 — 750 810 1,143 —
(DENYO/MQ GENERATOR)
a These dimensions are given for reference when the engine is set on a test bench.
*1: The electric priming pump switch is installed to the chassis.
*2: The manual priming pump is installed to the engine.
125E-5 Series 47
SEN00182-07 01 Specification
Weight table 1
(with EGR)
Unit: kg
No. Item Main parts SAA6D125E-5
1 Turbocharger KOMATSU KTR90 17
Cylinder head, valve,
2 Cylinder head assembly 15
valve spring
Cylinder block, bearing,
3 Cylinder block assembly 305
cap, cylinder liner
4 Front cover 29
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8,PC400LC-8 18
PC450-8,PC450LC-8
BR580JG-1
5 Oil pan D85EX-15E0, D85PX-15E0 21
WA450-6, WA470-6
WA480-6 22
HM250-2, HM300-2
DCA-300SSK4
35
(DENYO/MQ GENERATOR)
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8 49
PC450-8, PC450LC-8
BR580JG-1
6 Flywheel assembly Flywheel ring gear D85EX-15E0, D85PX-15E0 55
WA450-6, WA470-6
27
WA480-6
HM250-2, HM300-2 23
DCA-300SSK4
118
(DENYO/MQ GENERATOR)
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8
54
PC450-8, PC450LC-8
BR580JG-1
7 Flywheel housing assembly D85EX-15E0, D85PX-15E0
WA450-6, WA470-6,
WA480-6 47
HM250-2, HM300-2
DCA-300SSK4
64
(DENYO/MQ GENERATOR)
48 125E-5 Series
01 Specification SEN00182-07
Unit: kg
No. Item Main parts SAA6D125E-5
8 Crankshaft assembly Crankshaft, crank gear 106
Camshaft, cam gear,
9 Camshaft assembly 16
thrust plate
Piston and connecting rod Piston, piston ring,
10 8
assembly piston pin, connecting rod
11 Oil pump 5
12 Fuel supply pump 10
13 Water pump 10
24V, 35A 8
24V, 50A 10
14 Alternator
24V, 60A 11
24V, 75A 13
24V, 7.5kW 16
15 Starting motor
24V, 11kW 18
16 EGR oil pump 6
17 EGR valve 16
18 Bypass valve 16
19 EGR cooler 9
125E-5 Series 49
SEN00182-07 01 Specification
(EGR-less)
Unit: kg
No. Item Main parts SAA6D125E-5
1 Turbocharger KOMATSU KTR90 17
Cylinder head, valve,
2 Cylinder head assembly 15
valve spring
Cylinder block, bearing,
3 Cylinder block assembly 305
cap, cylinder liner
4 Front cover 29
PC400-8R, PC400LC-8R
PC450-8R, PC450LC-8R 18
PC500LC-8R
5 Oil pan D85EX-15R, D85PX-15R
21
GD755-5R
HM300-2R
22
WA470-6R, WA480-6R
PC400-8R, PC400LC-8R
PC450-8R, PC450LC-8R 49
PC500LC-8R
6 Flywheel assembly Flywheel ring gear D85EX-15R, D85PX-15R 55
WA470-6R, WA480-6R 27
HM300-2R 23
GD755-5R 56
PC400-8R, PC400LC-8R
PC450-8R, PC450LC-8R
PC500LC-8R 54
7 Flywheel housing assembly D85EX-15R, D85PX-15R
GD755-5R
HM300-2R
47
WA470-6R, WA480-6R
8 Crankshaft assembly Crankshaft, crank gear 106
Camshaft, cam gear,
9 Camshaft assembly 16
thrust plate
Piston and connecting rod Piston, piston ring,
10 8
assembly piston pin, connecting rod
11 Oil pump 5
12 Fuel supply pump 10
13 Water pump 10
24V, 50A 10
14 Alternator 24V, 60A 11
24V, 75A 13
24V, 7.5kW 16
15 Starting motor
24V, 11kW 18
50 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 51
SEN00182-07 01 Specification
SAA6D125E-5
(Applicable machine: PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R,
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R, PC500LC-8R)
Rated output: 262.5 kW {352 HP}/1,900 rpm (Gross)
Max. torque: 1,423 Nm {145 kgm}/1,400 rpm (Gross)
52 125E-5 Series
01 Specification SEN00182-07
SAA6D125E-5
(Applicable machine: D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R)
125E-5 Series 53
SEN00182-07 01 Specification
54 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 55
SEN00182-07 01 Specification
56 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 57
SEN00182-07 01 Specification
58 125E-5 Series
01 Specification SEN00182-07
125E-5 Series 59
SEN00182-07
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
60
SEN00184-07
125E-5 Series
SEN00184-05
ENGINE
Shop Manual
125E-5 Series
10 Structure,function and
maintenance standard
Structure, function and maintenance
standard, Part 1
125E-5 Series 1
SEN00184-07 10 Structure,function and maintenance standard
2 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 3
SEN00184-07 10 Structure,function and maintenance standard
General structure
4 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Engine
Name: SAA6D125E-5 (with turbocharger and air-cooled aftercooler)
Type : In-line 6-cylinder, water-cooled, direct injection, 4-stroke diesel engine
125E-5 Series 5
SEN00184-07 10 Structure,function and maintenance standard
6 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
A: To EGR cooler
B: To turbocharger
C: From bypass valve
125E-5 Series 7
SEN00184-07 10 Structure,function and maintenance standard
A: To turbocharger
8 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 9
SEN00184-07 10 Structure,function and maintenance standard
Air cleaner
10 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Structure Operation
q The size of the body is reduced from the conven- q Air containing dust is sucked in vertically through
tional type without changing the diameter of the inlet (1) and the dust is separated by the centrif-
element. ugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the sim- mary element (4) and clean air is sucked in the
ple spiral guide vane, not by the guide plate. engine through safety element (5) and outlet (2).
q The dust and water separated by guide vane (3)
swirl along the inside wall of body (9) and enter
evacuator valve (6) and then are discharged out
automatically.
125E-5 Series 11
SEN00184-07 10 Structure,function and maintenance standard
Turbocharger
(with EGR)
Model name: KTR90
12 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model name: KOMATSU KTR90
Overall length: 268 mm
Overall width: 247 mm
Overall height: 227 mm
Weight: 17 kg
125E-5 Series 13
SEN00184-07 10 Structure,function and maintenance standard
Unit: mm
14 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 15
SEN00184-07 10 Structure,function and maintenance standard
(EGR-less)
Model name: KTR90
16 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model name: KOMATSU KTR90
Overall length: 268 mm
Overall width: 247 mm
Overall height: 227 mm
Weight: 17 kg
125E-5 Series 17
SEN00184-07 10 Structure,function and maintenance standard
Unit: mm
18 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Aftercooler
Air-cooled type
1. Tank
2. Side support
3. Tube
4. Fin
125E-5 Series 19
SEN00184-07 10 Structure,function and maintenance standard
EGR system
4 Venturi system q Generates negative pressure with the venturi effect and takes in the exhaust gas.
q Controls the EGR according to the operating condition.
5 Each sensor
q Troubleshoots the system.
Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and trouble-
shooted, a serious trouble is prevented.
20 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 21
SEN00184-07 10 Structure,function and maintenance standard
22 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor
7. Bypass piping
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for open-
ing EGR valve (1) most properly according to the
load on the engine to attain both clean exhaust
gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust gas
(EGR gas) flows from the exhaust manifold
through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3) flows
through EGR valve (1) and mixes with the intake
air in venturi system (4), and then flows in the air
intake manifold.
q In the operating range where the boost pressure
is higher than the exhaust pressure on the high
load side, the EGR gas does not flow to the air
intake side easily. At this time, the engine con-
troller opens bypass valve (2).
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the ex-
haust pressure rises and more EGR gas mixes
with the intake air.
125E-5 Series 23
SEN00184-07 10 Structure,function and maintenance standard
24 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
EGR cooler
Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to in-
crease the gas density, or the EGR efficiency.
Structure
q The EGR cooler is a multi-tube heat exchanger.
When the high-temperature EGR gas flows
through heat exchange tube (1), it is cooled by
the coolant flowing outside of the tube.
q Heat exchange tube (1) is made of corrosion-re-
sistant stainless steel and corrugated to in-
crease the cooling efficiency.
125E-5 Series 25
SEN00184-07 10 Structure,function and maintenance standard
Venturi system
Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), venturi
nozzle (1), and diffuser (3).
Operation
q The boost pressure increased by the turbo-
charger is set negative temporarily with the ven-
turi effect of the throat to take the EGR gas into
the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake air
flows through diffuser (3), its pressure is in-
creased again to the normal level and then it
flows in the intake manifold.
26 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Cylinder head
125E-5 Series 27
SEN00184-07 10 Structure,function and maintenance standard
Cylinder head
q Direct injection type
q 4-valve type
q Overhead injector (Common rail system specification)
q Split-type 1-cylinder, 1-head
Valve seat
q Valve seat inserts are press fitted to both intake and exhaust valves
Head cover
q Float-type seal
28 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Unit: mm
Engine Standard
Replace nozzle
2 Projection of nozzle
SAA6D125E - 5 3.20–3.90 sleeve
125E-5 Series 29
SEN00184-07 10 Structure,function and maintenance standard
Cylinder block
1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. Liner ring (Ethylene-propylene rubber)
5. Liner ring (Silicone rubber)
6. Front seal
7. Front cover
8. Main cap bolt
9. Main bearing cap
10. Main bearing
11. Thrust bearing
12. Piston cooling nozzle
30 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: 7 bearings
Front seal
q Single lip with dust seal
Piston cooling
q With piston cooling nozzle
Cylinder liner
q Wet type
q Machining on inside: Plateau honing
Soft nitriding process
Liner ring
q Upper: Clevis seal
q Middle: O-ring (Ethylene-propylene rubber)
q Lower: O-ring (Silicone rubber)
125E-5 Series 31
SEN00184-07 10 Structure,function and maintenance standard
Unit: mm
32 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Unit: mm
125E-5 Series 33
SEN00184-07 10 Structure,function and maintenance standard
Cylinder liner
Unit: mm
34 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 35
SEN00184-07 10 Structure,function and maintenance standard
36 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Crankshaft
Unit: mm
S.T.D. 80 79.88
125E-5 Series 37
SEN00184-07 10 Structure,function and maintenance standard
Camshaft
Unit: mm
38 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Unit: mm
125E-5 Series 39
SEN00184-07 10 Structure,function and maintenance standard
40 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Unit: mm
125E-5 Series 41
SEN00184-07 10 Structure,function and maintenance standard
Connecting rod
Unit: mm
Dimension c 240 —
42 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Without PTO
125E-5 Series 43
SEN00184-07 10 Structure,function and maintenance standard
44 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Unit: mm
125E-5 Series 45
SEN00184-07 10 Structure,function and maintenance standard
46 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
1. Flywheel housing
2. Seal
3. Flywheel
Number of Number of
Applicable machine teeth of internal teeth
ring gear of flywheel
DCA-300SSK4
(DENYO/MQ GENERA- 178 –
TOR)
Unit: mm
125E-5 Series 47
SEN00184-07 10 Structure,function and maintenance standard
Vibration damper
1. Vibration damper
2. Pin
3. Crankshaft pulley
4. Crankshaft pulley mounting bolt
5. Vibration damper mounting bolt
48 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Unit: mm
1 Outside check Rubber parts must be free from cracking and flaking.
125E-5 Series 49
SEN00184-07 10 Structure,function and maintenance standard
Timing gear
(with EGR)
50 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 51
SEN00184-07 10 Structure,function and maintenance standard
Unit: mm
52 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 53
SEN00184-07 10 Structure,function and maintenance standard
(EGR-less)
54 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 55
SEN00184-07 10 Structure,function and maintenance standard
Unit: mm
56 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 57
SEN00184-07 10 Structure,function and maintenance standard
Valve system
58 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 59
SEN00184-07 10 Structure,function and maintenance standard
Valve timing
60 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
125E-5 Series 61
SEN00184-07 10 Structure,function and maintenance standard
Unit: mm
Bend of valve stem Repair limit: 0.01 (Overall swing of indicator in 100 mm) Replace
62 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Unit: mm
125E-5 Series 63
SEN00184-07 10 Structure,function and maintenance standard
Unit: mm
64 125E-5 Series
10 Structure,function and maintenance standard SEN00184-07
Unit: mm
125E-5 Series 65
SEN00184-07 10 Structure,function and maintenance standard
©2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
66
SEN00185-07
125E-5 Series
125E-5 Series 1
SEN00185-07 10 Structure, function and maintenance standard
Fuel piping.......................................................................................................................................... 40
Fuel filter............................................................................................................................................. 42
Electric priming pump......................................................................................................................... 44
Engine controller cooler...................................................................................................................... 45
Cooling system.............................................................................................................................................. 46
Cooling system diagram..................................................................................................................... 46
Water pump ........................................................................................................................................ 48
Thermostat ......................................................................................................................................... 50
Electrical equipment...................................................................................................................................... 52
Alternator............................................................................................................................................ 52
Starting motor ..................................................................................................................................... 60
Electrical intake air heater .................................................................................................................. 64
Engine controller ................................................................................................................................ 65
2 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 3
SEN00185-07 10 Structure, function and maintenance standard
Lubrication system 1
Lubrication system diagram 1
(with EGR)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
4 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
10. Piston cooling nozzle
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. EGR oil pump
20. EGR oil pump relief valve
21. EGR valve
22. Bypass valve
23. Main gallery
24. Oil filter clogging switch (for DCA-300SSK4)
125E-5 Series 5
SEN00185-07 10 Structure, function and maintenance standard
(EGR-less)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
6 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
10. Piston cooling nozzle
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. Main gallery
125E-5 Series 7
SEN00185-07 10 Structure, function and maintenance standard
Oil pump 1
1. Oil pump drive gear (Number of teeth: 21) Oil pump gear
2. Bushing Type: Gear pump
3. Pump cover Speed: Engine speed × 1.571
4. Drive gear
5. Pump body Main relief valve
6. Drive shaft Cracking pressure:
7. Main relief valve 0.65 – 0.8 MPa {6.63 – 8.16 kg/cm2}
8. Valve spring
9. Retainer
10. Drive shaft
11. Bushing
12. Driven gear
8 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
Unit: mm
No. Check item Criteria Remedy
Cracking pressure of 2 Correct or
1 Standard: 0.65 – 0.8 MPa {6.63 – 8.16 kg/cm }
relief valve replace spring
125E-5 Series 9
SEN00185-07 10 Structure, function and maintenance standard
10 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
Oil filter 1
Remote mount type
125E-5 Series 11
SEN00185-07 10 Structure, function and maintenance standard
12 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
Safety valve 1
1. Safety valve
2. Filter head
3. Spring
4. Cap
Unit: mm
No. Check item Criteria Remedy
Cracking pressure of safety
1 Standard: 343 ± 19 kPa {3.5 ± 0.2 kg/cm2} Replace
valve
125E-5 Series 13
SEN00185-07 10 Structure, function and maintenance standard
Oil cooler 1
Unit: mm
No. Check item Criteria Remedy
Min. 8 mm
Full opening lift of thermostat SAA6D125E-5
(Check after soaking in oil tank at 85°C for 4 – 5 minutes)
6 Replace
Opening and closing of ther- When valve full open (at 85°C) is soaked in oil tank at full closing tempera-
mostat ture (71°C), it must close fully in 4 – 5 minutes.
14 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 15
SEN00185-07 10 Structure, function and maintenance standard
Fuel system 1
CRI system diagram 1
(with EGR)
a CRI is an abbreviation for Common Rail Injection. Hereinafter, the common rail injection is referred to
as the CRI.
16 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
(EGR-less)
a CRI is an abbreviation for Common Rail Injection. Hereinafter, the common rail injection is referred to
as the CRI.
125E-5 Series 17
SEN00185-07 10 Structure, function and maintenance standard
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
18 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
2. Control system
a Parts marked with * (2 places) are installed to only the engines with EGR.
125E-5 Series 19
SEN00185-07 10 Structure, function and maintenance standard
q The CRI system consists of the fuel supply q If the TWV is turned on (energized), the fuel
pump, common rail, injector, engine controller circuit is so changed that the high-pressure
to control them, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The discharge rate is controlled by turning on q If the TWV is turned off (de-energized), the fuel
and off the PCV (pressure control valve) of the circuit is so changed that the high-pressure
fuel supply pump according to the electric sig- fuel will be applied to the control chamber
nals from the engine controller. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers and finishes fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
20 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 21
SEN00185-07 10 Structure, function and maintenance standard
Operation
22 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 23
SEN00185-07 10 Structure, function and maintenance standard
2. Common rail
Structure Operation
q Common rail (4) distributes the high-pressure When fuel is not injected
fuel from the high-pressure pump to the injec-
q Piston (2) is in contact with stopper (1) (initial
tors of the cylinders.
position).
q Common rail (4) is equipped with common rail
q The fuel for static leakage is supplied through
fuel pressure sensor (2), flow dampers (1), and
orifice (a) of piston (2) and clearance in the
pressure limiter (3).
sliding parts.
q The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
When fuel is injected
the injectors.
q The fuel pressure is applied to piston (2),
q The piping of the pressure limiter (3) is
which compresses spring (3) and moves to the
returned to the fuel tank.
right.
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
When fuel is stopped
q If the fuel flows out abnormally because of a
burst of the piping, etc., piston (2) moves to the
right stroke end.
q The tip of piston (2) contacts seat (b) to stop
the fuel.
q Once the fuel is stopped, piston (2) does not
return to the initial position until the engine is
stopped.
1) Flow damper
Function
q The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
24 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
1. Ball
2. Housing
3. Spring
4. Body
5. Guide
125E-5 Series 25
SEN00185-07 10 Structure, function and maintenance standard
3. Injector
Outline
q The function of the injector is to inject the high-
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
26 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
Structure
125E-5 Series 27
SEN00185-07 10 Structure, function and maintenance standard
Operation
28 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 29
SEN00185-07 10 Structure, function and maintenance standard
Various controls
a Parts marked with * (3 places) are installed to only the engines with EGR.
q The CRI system controls the fuel injection rate 2. Fuel injection timing control function
and fuel injection timing more properly than the q The fuel injection timing control function is
mechanical governor or timer of the conven- employed instead of the function of the con-
tional fuel injection pump. ventional timer. It controls the fuel injection
q For the control of the system, calculations nec- timing most properly from the engine speed
essary to the engine controller are performed and fuel injection rate.
fr om th e si gn als se nt fr om the s en so r s
installed to the engine and machine.
q The energizing timing and energizing period of 3. Fuel injection pressure control function
the injector are so controlled that the optimum (Common rail fuel pressure control function)
quantity of fuel will be injected in the optimum q The fuel injection pressure control function
timing. (common rail fuel pressure control function) is
a function of measuring the fuel pressure with
the common rail fuel pressure sensor and
1. Fuel injection rate control function feeding it back to the engine controller to con-
q The fuel injection rate control function is trol the delivery of the fuel supply pump.
employed instead of the function of the con- q This function performs pressure feedback con-
ventional governor. It controls the fuel injection trol so that the fuel injection pressure will be
according to the signals of engine speed and the same as the optimum value (command
accelerator angle so that the fuel injection rate value) set according to the engine speed and
will be most proper. fuel injection rate.
30 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 31
SEN00185-07 10 Structure, function and maintenance standard
4. Various sensors
32 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 33
SEN00185-07 10 Structure, function and maintenance standard
A: Pressure inlet
B: Mounting screw: M5
Tightening torque: 4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
34 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 35
SEN00185-07 10 Structure, function and maintenance standard
8) Engine controller
36 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
A: Mounting screw: M6
Tightening torque: 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring
125E-5 Series 37
SEN00185-07 10 Structure, function and maintenance standard
38 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 39
SEN00185-07 10 Structure, function and maintenance standard
Fuel piping 1
40 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
A: Fuel inlet
B: To fuel filter
C: From fuel filter
D: To injector
E: Fuel return (between overflow valve and fuel
tank)
F: Fuel return (between injector and fuel tank)
G: Engine oil (to fuel supply pump)
Specifications
Fuel supply pump
Manufacturer: DENSO CORPORATION
Model: DENSO ECD-U2
Lubrication method: Forced lubrication with engine oil
125E-5 Series 41
SEN00185-07 10 Structure, function and maintenance standard
Fuel filter 1
Main fuel filter
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.0 m2
42 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
Specifications
Filtration area: 1.06 m2
125E-5 Series 43
SEN00185-07 10 Structure, function and maintenance standard
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
44 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
1. Engine controller
2. Engine controller cooler
Outline
q The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
q The fuel is not circuited in some applicable
machines.
125E-5 Series 45
SEN00185-07 10 Structure, function and maintenance standard
Cooling system 1
Cooling system diagram 1
(with EGR)
46 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
(EGR-less)
125E-5 Series 47
SEN00185-07 10 Structure, function and maintenance standard
Water pump 1
Mounting
48 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
a. From thermostat
b. From radiator
c. To each part of engine
Water pump
Type: Centrifugal, gear-driven
Speed: Engine speed × 1.5
Unit: mm
No. Check item Criteria Remedy
Tolerance Standard inter- Replace
Standard size
Interference of impeller Shaft Hole ference Usually, impeller needs to be
8
and shaft replaced (Outside diameter of
+0.018 –0.020
15.9 0.025 – 0.068 shaft changes little)
+0.005 –0.050
Interference of drive gear +0.015 –0.023 Replace (Usually, gear needs to
9 20.0 0.025 – 0.068
and shaft +0.002 –0.053 be replaced)
Clearance between impel-
10 Standard clearance: 0.30 – 1.10 (including end play)
ler and body Replace
11 Wear of water seal ring Limits of size: 1.5
125E-5 Series 49
SEN00185-07 10 Structure, function and maintenance standard
Thermostat 1
Mounting
a. To radiator
b. To water pump
1. Thermostat
2. Thermostat housing
50 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
Unit: mm
No. Check item Criteria Remedy
Full opening lift of thermostat Min. 10 mm (Check after soaking in oil tank at 90°C for 4 – 5 minutes.)
1 Opening and closing of When valve full open (at 90°C) is soaked in oil tank at full closing temper- Replace
thermostat ature (71°C) , it must close fully in 4 – 5 minutes.
125E-5 Series 51
SEN00185-07 10 Structure, function and maintenance standard
Electrical equipment 1
Alternator 1
1. Alternator with built-in regulator (Open type, 35 A)
Pulley
Weight
Engine Applicable machine Type Specification Number Outside
diameter (kg)
of stages
(mm)
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0 Open type (brushless),
SAA6D125E-5 BR580JG-1 manufactured by NIKKO 24V, 35A 2 93 8.0
DCA-300SSK4 DENKI
(DENYO/MQ GENERATOR)
52 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
Pulley
Weight
Engine Applicable machine Type Specification Number Outside
diameter (kg)
of stages
(mm)
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8,
PC400-8R, PC400LC-8R
PC450-8, PC450LC-8,
PC450-8R, PC450LC-8R,
Open type (brushless),
PC500LC-8R,
SAA6D125E-5 manufactured by NIKKO 24V, 50A 2 75 10
D85EX-15E0, D85EX-15R
DENKI
D85PX-15E0, D85PX-15R
WA450-6, WA470-6,
WA470-6R
WA480-6, WA480-6R
HM250-2, HM300-2,
HM300-2R
125E-5 Series 53
SEN00185-07 10 Structure, function and maintenance standard
a. Load
1. Alternator 5. Terminal E
2. Alternator pulley 6. Internal electric circuit diagram
3. Terminal B 6A. Field coil
4. Terminal R 6B. Primary energized resistance
6C. Regulator
Pulley
Weight
Engine Applicable machine Type Specification Number Outside
diameter (kg)
of stages
(mm)
PC400-8, PC400LC-8
PC450-8, PC450LC-8
Open type, manufactured by
SAA6D125E-5 PC400-8R, PC400LC-8R 24V, 60A 2 85 11
NIKKO DENKI
PC450-8R, PC450LC-8R
PC500LC-8R
54 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
a. Load
1. Alternator
2. Alternator pulley
3. Terminal R
4. Terminal E
5. Terminal B
6. Internal electric circuit diagram
6A. Alternator
6B. Regulator
Pulley
Weight
Engine Applicable machine Type Specification Number Outside
diameter (kg)
of stages
(mm)
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
HM250-2, HM300-2,
HM300-2R Open type, manufactured
SAA6D125E-5 24V, 75A 2 95 13
WA450-6, WA470-6, by SAWAFUJI DENKI
WA480-6
WA470-6R, WA480-6R
GD755-5R
125E-5 Series 55
SEN00185-07 10 Structure, function and maintenance standard
Alternator mounting
1. Alternator pulley
2. Alternator drive belt
3. Crankshaft pulley
4. Adjustment bolt
56 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
1. Alternator pulley
2. Alternator drive belt
3. Crankshaft pulley
4. Adjustment bolt
125E-5 Series 57
SEN00185-07 10 Structure, function and maintenance standard
1. Alternator pulley
2. Alternator drive belt
3. Crankshaft pulley
4. Adjustment bolt
58 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
125E-5 Series 59
SEN00185-07 10 Structure, function and maintenance standard
Starting motor 1
Starting motor with built-in safety relay (7.5 kW)
60 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
1. Pinion gear
2. Starting motor (body)
3. Magnetic switch
4. External electric circuit diagram [2P connector (male)]
4A. Safety relay
4B. Starting motor
5. External electric circuit diagram [3P connector (male)]
5A. Safety relay
5B. Starting motor
6. Specifications of connector
Type A: 2P connector (male)
Type B: 2P dust-proof connector (male)
Type C: 3P dust-proof connector (male)
Type D: 2P connector (male)
B, C, R, S, E: Terminals
125E-5 Series 61
SEN00185-07 10 Structure, function and maintenance standard
62 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
1. Pinion gear
2. Starting motor (body)
3. Magnetic switch
4. External electric circuit diagram
4A. Safety relay
4B. Starting motor
5. Specifications of connector
Type A: 2P connector (male)
Type B: Dust-proof connector (male)
B, C, R, S, E: Terminals
125E-5 Series 63
SEN00185-07 10 Structure, function and maintenance standard
1. Terminal
2. Body
3. Heater coil
4. Electric circuit diagram
64 125E-5 Series
10 Structure, function and maintenance standard SEN00185-07
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q The engine controller cooler (if equipped) is
prepared to cool the engine controller with the
fuel to secure the reliability of the mounted
engine controller.
q Vibrations are damped by the vibration-proof
rubber.
125E-5 Series 65
SEN00185-07
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
66
SEN00546-10
125E-5 Series
125E-5 Series 1
SEN00546-10 20 Standard value table
Min. 80°C
Engine oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.08 0.05
Engine oil temperature: SAE30DH {kg/cm2} {Min. 0.8} {0.5}
Min. 80°C
Engine oil tempera-
Whole speed range (In oil pan) °C 90 – 110 120
ture
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.15 0.3
rated output
Function of radiator kPa
Cracking pressure (Differential pressure) — —
pressure valve {kg/cm2}
Cooling system
2 125E-5 Series
20 Standard value table SEN00546-10
Engine SAA6D125E-5
D85EX-15R
Machine model
D85PX-15R
Performance Category
kPa Min. 87 73
Exhaust pressure At rated output
{mmHg} {Min. 650} {550}
Exhaust temperature Whole speed range (20°C) °C 650 700
%
Max. 40
At sudden acceleration (Low o High) (Bosch —
{Max. 4.0}
index)
Exhaust gas color Bosch
At rated output Max. 1.5 —
index
Bosch
At high idle Max. 1.0 —
index
Intake valve mm 0.33 —
Valve clearance
Exhaust valve mm 0.71 —
Compression pres- Engine oil temperature: 40 – 60°C MPa Min. 2.9 2.0
sure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 30} {20}
Body
125E-5 Series 3
SEN00546-10 20 Standard value table
Engine SAA6D125E-5
PC400, 400LC-7E0,
PC400, 400LC-8
Machine model
PC450, 450LC-7E0,
PC450, 450LC-8
Performance Category
4 125E-5 Series
20 Standard value table SEN00546-10
Engine SAA6D125E-5
PC400, 400LC-8R
Machine model
PC450, 450LC-8R, PC500LC-8R
Performance Category
125E-5 Series 5
SEN00546-10 20 Standard value table
Engine SAA6D125E-5
Machine model HM250-2
Performance Category
6 125E-5 Series
20 Standard value table SEN00546-10
Engine SAA6D125E-5
Machine model HM300-2
Performance Category
125E-5 Series 7
SEN00546-10 20 Standard value table
Engine SAA6D125E-5
Machine model HM300-2R
Performance Category
8 125E-5 Series
20 Standard value table SEN00546-10
Engine SAA6D125E-5
Machine model WA450-6, WA480-6
Performance Category
125E-5 Series 9
SEN00546-10 20 Standard value table
Engine SAA6D125E-5
Machine model WA470-6R
Performance Category
10 125E-5 Series
20 Standard value table SEN00546-10
Engine SAA6D125E-5
Machine model WA480-6
Performance Category
125E-5 Series 11
SEN00546-10 20 Standard value table
Engine SAA6D125E-5
Machine model WA480-6R
Performance Category
12 125E-5 Series
20 Standard value table SEN00546-10
Engine SAA6D125E-5
Machine model BR580JG-1
Performance Category
125E-5 Series 13
SEN00546-10 20 Standard value table
Engine SAA6D125E-5
Machine model GD755-5R
Performance Category
14 125E-5 Series
20 Standard value table SEN00546-10
Engine SAA6D125E-5
DCA-300SSK4
Machine model
(DENYO/MQ GENERATOR)
Performance Category
125E-5 Series 15
SEN00546-10 20 Standard value table
Running-in standard
Engine SAA6D125E-5
D85EX-15E0, D85EX-15R
Machine model
D85PX-15E0, D85PX-15R
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 750 950 1,140 1,425 1,900
Dynamometer
N {kg} 0 {0} 275 {28} 697 {71} 1,115 {114} 1,394 {142}
load
Output kW {HP} 0 {0} 20 {26.6} 60 {80} 119 {160} 199 {266}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
D85EX-15E0, D85EX-15R
Machine model
D85PX-15E0, D85PX-15R
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 1,900 1,400 2,100 ± 50 750 (+50/0)
Dynamometer N 1,354 – 1,432 1,727 – 1,834
— —
load {kg} {138 – 146} {176 – 187}
Output kW 199
— — —
(Gross value) {HP} {266}
Torque Nm 1,272
— — —
(Gross value) {kgm} {130}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 650 Max. 650 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
16 125E-5 Series
20 Standard value table SEN00546-10
Running-in standard
Engine SAA6D125E-5
PC400, 400LC-7E0, PC400, 400LC-8, PC400, 400LC-8R
Machine model
PC450, 450LC-7E0, PC450, 450LC-8, PC450, 450LC-8R, PC500LC-8R
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 1,000 1,000 1,200 1,500 1,900
Dynamometer
N {kg} 0 {0} 353 {36} 875 {89} 1,400 {143} 1,893 {193}
load
Output kW {HP} 0 {0} 26 {35.5} 79 {106} 157 {211} 262.5 {352}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
PC400, 400LC-7E0, PC400, 400LC-8, PC400, 400LC-8R
Machine model
PC450, 450LC-7E0, PC450, 450LC-8, PC450, 450LC-8R, PC500LC-8R
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 1,900 1,400 1,930 ± 50 1,000 ± 25
Dynamometer N 1,785 – 1,900 1,920 – 2,050
— —
load {kg} {182 – 194} {196 – 209}
Output kW 262.5
— — —
(Gross value) {HP} {352}
Torque Nm 1,422
— — —
(Gross value) {kgm} {145}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 700 Max. 700 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
125E-5 Series 17
SEN00546-10 20 Standard value table
Running-in standard
Engine SAA6D125E-5
Machine model HM250-2
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 725 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 307 {31} 774 {79} 1,238 {126} 1,547 {158}
load
Output kW {HP} 0 {0} 23 {31} 70 {94} 139 {186} 232 {311}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
Machine model HM250-2
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 2,000 1,400 2,100 ± 50 725 (+50/0)
Dynamometer N 1,500 – 1,593 2,320 – 2,450
— —
load {kg} {153 – 162} {236 – 250}
Output kW 232
— — —
(Gross value) {HP} {311}
Torque Nm 1,706
— — —
(Gross value) {kgm} {174}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 700 Max. 750 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
18 125E-5 Series
20 Standard value table SEN00546-10
Running-in standard
Engine SAA6D125E-5
Machine model HM300-2, HM300-2R
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 725 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 343 {35} 850 {87} 1,354 {138} 1,692 {173}
load
Output kW {HP} 0 {0} 26 {34.5} 76 {103} 152 {204} 254 {340}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
Machine model HM300-2, HM300-2R
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 2,000 1,400 2,220 ± 50 725 (+50/0)
Dynamometer N 1,650 – 1,750 2,320 – 2,450
— —
load {kg} {168 – 178} {236 – 250}
Output kW 254
— — —
(Gross value) {HP} {340}
Torque Nm 1,706
— — —
(Gross value) {kgm} {174}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 700 Max. 750 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
125E-5 Series 19
SEN00546-10 20 Standard value table
Running-in standard
Engine SAA6D125E-5
WA450-6
Machine model
WA470-6, WA470-6R
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 800 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 275 {28} 677 {69} 1,079 {110} 1,353 {138}
load
Output kW {HP} 0 {0} 21 {27.6} 61 {82} 121 {163} 203 {272}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
WA450-6
Machine model
WA470-6, WA470-6R
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 2,000 1,450 2,170 ± 50 800 (+50/0)
Dynamometer N 1,319 – 1,400 1,267 – 1,345
— —
load {kg} {135 – 143} {129 – 137}
Output kW 204
— — —
(Gross value) {HP} {273}
Torque Nm 1,307
— — —
(Gross value) {kgm} {133}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 650 Max. 650 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
20 125E-5 Series
20 Standard value table SEN00546-10
Running-in standard
Engine SAA6D125E-5
Machine model WA480-6, WA480-6R
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 800 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 294 {30} 735 {75} 1,196 {122} 1,491 {152}
load
Output kW {HP} 0 {0} 22 {29.6} 66 {89} 135 {180} 224 {300}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
Machine model WA480-6, WA480-6R
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 2,000 1,400 2,190 ± 50 800 (+50/0)
Dynamometer N 1,450 – 1,541 1,843 – 1,956
— —
load {kg} {148 – 157} {188 – 200}
Output kW 224
— — —
(Gross value) {HP} {301}
Torque Nm 1,360
— — —
(Gross value) {kgm} {139}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 700 Max. 700 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
125E-5 Series 21
SEN00546-10 20 Standard value table
Running-in standard
Engine SAA6D125E-5
Machine model BR580JG-1
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 1,000 1,000 1,200 1,500 1,900
Dynamometer
N {kg} 0 {0} 353 {36} 875 {89} 1,400 {143} 1,893 {193}
load
Output kW {HP} 0 {0} 26 {35.5} 79 {106} 157 {211} 262.5 {352}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
Machine model BR580JG-1
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 1,900 1,400 1,930 ± 50 1,000 ± 25
Dynamometer N 1,785 – 1,900 1,920 – 2,050
— —
load {kg} {182 – 194} {196 – 209}
Output kW 262.5
— — —
(Gross value) {HP} {352}
Torque Nm 1,422
— — —
(Gross value) {kgm} {145}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 700 Max. 700 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
22 125E-5 Series
20 Standard value table SEN00546-10
Running-in standard
Engine SAA6D125E-5
Machine model GD755-5R
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 800 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 288 {29} 720 {73} 1,152 {117} 1,440 {147}
load
Output kW {HP} 0 {0} 21.6 {29.0} 64.8 {86.9} 129.6 {173.8} 216 {289.7}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
Machine model GD755-5R
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 2,000 1,400 2,200 ± 50 800 (+50/0)
Dynamometer N 1,397 – 1,483 1,784 – 1,894
— —
load {kg} {142.5 – 151.3} {181.9 – 193.1}
Output kW 216
— — —
(Gross value) {HP} {289.7}
Torque Nm 1,317
— — —
(Gross value) {kgm} {134.3}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 700 Max. 700 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
125E-5 Series 23
SEN00546-10 20 Standard value table
Running-in standard
Engine SAA6D125E-5
DCA-300SSK4
Machine model
(DENYO/MQ GENERATOR)
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 750 1,500 1,500 1,500 1,800
Dynamometer
N {kg} 0 {0} 366 {37} 970 {99} 1,568 {160} 2,019 {206}
load
Output kW {HP} 0 {0} 41 {56} 109 {148} 177 {240} 277 {370}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Engine SAA6D125E-5
DCA-300SSK4
Machine model
(DENYO/MQ GENERATOR)
Max. speed at no Min. speed at no
Test item Rated output Max. output
load load
Specification
kW 272 ± 7.36 313 ± 9.56
value
{HP} {365 ± 10} {420 ± 13}
(Gross value)
Speed rpm 1,800 1,800 Max. 1,890 750 ± 25
Dynamometer N 1,960 – 2,068 2,244 – 2,391
— —
load {kg} {200 – 211} {229 – 244}
Output kW 272
— — —
(Gross value) {HP} {370}
Torque Nm
— — — —
(Gross value) {kgm}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 690 190 – 540 290 – 690 Min. 80
pressure {kg/cm2} {3.0 – 7.0} {2.0 – 5.5} {3.0 – 7.0} {Min. 0.8}
Exhaust
°C Max. 700 Max. 750 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
24 125E-5 Series
20 Standard value table SEN00546-10
125E-5 Series 25
SEN00546-10
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 03-17 (01)
26
SEN00547-05
125E-5 Series
125E-5 Series 1
SEN00547-05 30 Testing and adjusting
2 125E-5 Series
30 Testing and adjusting SEN00547-05
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
Testing air boost pressure A
799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Commercially Intake: 0.33 mm
Adjusting valve clearance C Feeler gauge 1
available Exhaust: 0.71 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1420 Adapter 1
pressure 2 For 125E-5
6217-71-6112 Gasket 1
Testing blow-by pressure E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing oil pressure F
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing fuel pressure G
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1
3 8 x 1.25 mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 φ 5 mm x 2 – 3 m
available
Testing leakage from
Commercially
pressure limiter and return H 4 Hose 1 φ 15 mm x 2 – 3 m
rate from injector available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
125E-5 Series 3
SEN00547-05 30 Testing and adjusting
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
799-601-4130 T-adapter — For Ne sensor
799-601-4330 Socket — For Bkup sensor
799-601-4240 Socket — For atmospheric pressure sensor
799-601-4250 Socket — For boost pressure sensor
799-601-4180 T-adapter — For EGR gas sensor
799-601-9420 T-adapter — For common rail pressure
799-601-4150 T-adapter — For oil pressure sensor
795-799-5540 T-adapter — For boost temperature sensor
For coolant temperature sensor
795-799-5530 T-adapter —
For fuel temperature sensor
Troubleshooting for
For EGR valve solenoid
controllers, J 799-601-9020 T-adapter —
For bypass valve solenoid
sensors, and actuators
For EGR valve solenoid
799-601-9030 T-adapter —
For bypass valve stroke sensor
799-601-9430 T-adapter — For supply pump PCV
799-601-9020 T-adapter — For injector
799-601-4260 T-adapter — For controller (4-pole)
799-601-4210 T-adapter — For controller (50-pole)
799-601-4220 T-adapter — For controller (60-pole)
799-601-9320 T-box —
For 24-pole type
799-601-9310 Plate —
799-601-4350 T-box — For 60-pole type
21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
Socket 1
available Applicable engine serial No.:
Removal and installation 560001 - 564999
of engine coolant —
temperature sensor 19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
795T-981-1010 Socket 1
Applicable engine serial No.:
565000 and up
4 125E-5 Series
30 Testing and adjusting SEN00547-05
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
125E-5 Series 5
SEN00547-05 30 Testing and adjusting
6 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 7
SEN00547-05 30 Testing and adjusting
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tools for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Feeler gauge 4. Insert feeler gauge C in the clearance between
available
rocker arm (5) and crosshead (6) and adjust
the valve clearance with adjustment screw (3).
1. Remove 6 cylinder head covers (1). a With the feeler gauge inserted, turn the
adjustment screw to a degree that you can
move the feeler gauge lightly.
a Valve clearance
Intake valve: 0.33 mm
Exhaust valve: 0.71 mm
8 125E-5 Series
30 Testing and adjusting SEN00547-05
Testing compression pressure 1 a Pass a wire, etc. under the fuel path pro-
jected sideways and pull up the injector
a Testing tools for compression pressure (Do not pry the injector top up).
1. Remove cylinder head cover (1) of the cylinder 4. Install adapter D2 to the mounting hole on the
to be tested for compression pressure. injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
125E-5 Series 9
SEN00547-05 30 Testing and adjusting
6. Connect the INSITE (bench test tool) to the 3 Rocker arm assembly mounting
engine and set the engine in the no-injection bolt:
cranking mode. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will a Adjust the valve clearance. For
be dangerous. Accordingly, be sure to details, see "Adjusting valve clear-
set the engine in this mode. ance".
7. Rotate the engine with the starting motor and 3 Cylinder head cover mounting bolt:
measure the compression pressure. 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
a Read the pressure gauge pointer when it
is stabilized.
10 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 11
SEN00547-05 30 Testing and adjusting
12 125E-5 Series
30 Testing and adjusting SEN00547-05
Measuring EGR valve and bypass 3. Connect hydraulic tester [1] to the nipple.
valve drive pressure 1
4. Start the engine and measure the oil pressure
a Measuring instruments for EGR valve and at low idle and high idle.
bypass valve drive pressure a When measuring without removing the
engine from the machine, measure under
Symbol Part No. Part name the condition described in the shield
799-101-5002 Hydraulic tester machine for the machine.
F 1
790-261-1204 Digital hydraulic tester
125E-5 Series 13
SEN00547-05 30 Testing and adjusting
14 125E-5 Series
30 Testing and adjusting SEN00547-05
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
range, it is normal.
Symbol Part No. Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
125E-5 Series 15
SEN00547-05 30 Testing and adjusting
16 125E-5 Series
30 Testing and adjusting SEN00547-05
Testing leakage from pressure limiter and return rate from injector 1
a The locations of the fuel circuit parts are sub- 1. Preparation work
ject to machine models (The figure shows the 1) Remove tube (3) between common rail (1)
engine for PC400/400LC-7E0 and PC450/ and return block (2).
450LC-7E0).
a Testing tools for leakage from pressure limiter
and return rate from injector
125E-5 Series 17
SEN00547-05 30 Testing and adjusting
18 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 19
SEN00547-05 30 Testing and adjusting
20 125E-5 Series
30 Testing and adjusting SEN00547-05
2. Install pre-fuel filter (1) to the filter head. 5. Loosen air bleeder (6) of the fuel supply pump
a Apply engine oil thinly over the packing on and operate priming pump (4) 90 – 100 times.
the pre-fuel filter side. a Operate the priming pump until the fuel
a After the packing of the pre-fuel filter flows out of the air bleeder and tighten the
touches the sealing face of the filter head, air bleeder. Then, operate the priming
tighten the fuel filter 3/4 turns. pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
125E-5 Series 21
SEN00547-05 30 Testing and adjusting
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
k
leakage.
Very high pressure is generated in the a Inspect mainly around the high-pressure
high-pressure circuit of the fuel system. If circuit parts coated with the color checker
fuel leaks while the engine is running, it is for fuel leakage.
dangerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, inspection is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
22 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 23
SEN00547-05 30 Testing and adjusting
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
Adjusting
a If the deflection is out of the standard range, 1. Loosen locknut (1) and bolts (2) and (3).
adjust it according to the following procedure.
a The figure shows an example. The number of 2. Move alternator (5) with adjustment nut (4) to
the belt may be different and locknut (1) may adjust the tension of belt (6).
not be used depending on each model.
3. Tighten bolts (3) and (2) and tighten locknut
1. Loosen locknut (1) and loosen rocknut (2) and (1).
bolts (3) and (4). 3 Bolt (3): 107.8 – 147 Nm {11 – 15 kgm}
3 Bolt (2): 28.4 – 38.2 Nm {2.9 – 3.9 kgm}
2. Move alternator (6) with adjustment nut (5) to a After adjusting, test the belt tension again.
adjust the tension of belt (7).
24 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 25
SEN00547-05 30 Testing and adjusting
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
Testing air boost pressure A
799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Commercially Intake: 0.33 mm
Adjusting valve clearance C Feeler gauge 1
available Exhaust: 0.71 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
D 795-471-1420 Adapter 1
pressure 2 For 125E-5
6217-71-6112 Gasket 1
Testing blow-by pressure E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing oil pressure F
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing fuel pressure G
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1
3 8 x 1.25 mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 φ 5 mm x 2 – 3 m
available
Testing leakage from
Commercially
pressure limiter and return H 4 Hose 1 φ 15 mm x 2 – 3 m
rate from injector available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
26 125E-5 Series
30 Testing and adjusting SEN00547-05
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
799-601-4130 T-adapter — For Ne sensor
799-601-4330 Socket — For Bkup sensor
799-601-4240 Socket — For atmospheric pressure sensor
799-601-4250 Socket — For boost pressure sensor
799-601-9420 T-adapter — For common rail pressure
799-601-4150 T-adapter — For oil pressure sensor
795-799-5540 T-adapter — For boost temperature sensor
Troubleshooting for For coolant temperature sensor
795-799-5530 T-adapter —
controllers, J For fuel temperature sensor
sensors, and actuators 799-601-9430 T-adapter — For supply pump PCV
799-601-9020 T-adapter — For injector
799-601-4260 T-adapter — For controller (4-pole)
799-601-4210 T-adapter — For controller (50-pole)
799-601-4220 T-adapter — For controller (60-pole)
799-601-9320 T-box —
For 24-pole type
799-601-9310 Plate —
799-601-4350 T-box — For 60-pole type
21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
Socket 1
available Applicable engine serial No.:
Removal and installation 560001 - 564999
of engine coolant —
temperature sensor 19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
795T-981-1010 Socket 1
Applicable engine serial No.:
565000 and up
125E-5 Series 27
SEN00547-05 30 Testing and adjusting
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
28 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 29
SEN00547-05 30 Testing and adjusting
30 125E-5 Series
30 Testing and adjusting SEN00547-05
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tools for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Feeler gauge 4. Insert feeler gauge C in the clearance between
available
rocker arm (5) and crosshead (6) and adjust
the valve clearance with adjustment screw (3).
1. Remove 6 cylinder head covers (1). a With the feeler gauge inserted, turn the
adjustment screw to a degree that you can
move the feeler gauge lightly.
a Valve clearance
Intake valve: 0.33 mm
Exhaust valve: 0.71 mm
125E-5 Series 31
SEN00547-05 30 Testing and adjusting
Testing compression pressure 1 a Pass a wire, etc. under the fuel path pro-
jected sideways and pull up the injector
a Testing tools for compression pressure (Do not pry the injector top up).
1. Remove cylinder head cover (1) of the cylinder 4. Install adapter D2 to the mounting hole on the
to be tested for compression pressure. injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
32 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 33
SEN00547-05 30 Testing and adjusting
34 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 35
SEN00547-05 30 Testing and adjusting
36 125E-5 Series
30 Testing and adjusting SEN00547-05
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
range, it is normal.
Symbol Part No. Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
125E-5 Series 37
SEN00547-05 30 Testing and adjusting
38 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 39
SEN00547-05 30 Testing and adjusting
3. Testing return rate from injector 6) After the engine speed is stabilized, test
a Keep the hose on the pressure limiter side the return rate in 1 minute with measuring
connected and keep its end in the pan while cylinder H5.
testing the return rate from the injector. a You may test for 20 seconds and
1) Disconnect fuel return hose (4) from return judge by multiplying the result by 3.
block (2). a If the supply pump is not supplying
a Stop the fuel return hose with a plug, fuel, the engine speed may not rise.
etc. and fix it to the fuel tank. In this case, record the engine speed,
Plug: 07376-70315 too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
40 125E-5 Series
30 Testing and adjusting SEN00547-05
Bleeding air from fuel circuit 1 4. Turn “ON” switch (3) of electric priming pump
(2) installed to the chassis.
Reference: The electric priming pump switch is a The electric priming pump operates and
installed to the chassis. lamp (4) blinks.
a Manual priming pump is set for some models.
(See the"with EGR")
a Bleed air from the fuel circuit in the following
cases according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first
time after the fuel piping or supply pump is
replaced
a If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
2. Check that the fuel valve on the fuel tank side a The electric priming pump has a timer in it
is open. to start and stop itself automatically (See
the following figure).
3. Turn lever (1) of the air bleeding piping to the a The electric priming pump stops while the
parallel position with the piping to open the cir- lamp is blinking. This phenomenon is not
cuit valve. abnormal, however.
a If the switch is turned to the “OFF” position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
k While the electric priming pump is
operating, pressure is applied to the
fuel circuit. Do not loosen the air
bleeding plug at this time, since the
fuel may spout out.
125E-5 Series 41
SEN00547-05 30 Testing and adjusting
42 125E-5 Series
30 Testing and adjusting SEN00547-05
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
k
leakage.
Very high pressure is generated in the a Inspect mainly around the high-pressure
high-pressure circuit of the fuel system. If circuit parts coated with the color checker
fuel leaks while the engine is running, it is for fuel leakage.
dangerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, inspection is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
125E-5 Series 43
SEN00547-05 30 Testing and adjusting
44 125E-5 Series
30 Testing and adjusting SEN00547-05
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
Adjusting
a If the deflection is out of the standard range, 1. Loosen locknut (1) and bolts (2) and (3).
adjust it according to the following procedure.
a The figure shows an example. The number of 2. Move alternator (5) with adjustment nut (4) to
the belt may be different and locknut (1) may adjust the tension of belt (6).
not be used depending on each model.
3. Tighten bolts (3) and (2) and tighten locknut
1. Loosen locknut (1) and loosen rocknut (2) and (1).
bolts (3) and (4). 3 Bolt (3): 107.8 – 147 Nm {11 – 15 kgm}
3 Bolt (2): 28.4 – 38.2 Nm {2.9 – 3.9 kgm}
2. Move alternator (6) with adjustment nut (5) to a After adjusting, test the belt tension again.
adjust the tension of belt (7).
125E-5 Series 45
SEN00547-05 30 Testing and adjusting
46 125E-5 Series
30 Testing and adjusting SEN00547-05
125E-5 Series 47
SEN00547-05
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10
48
SEN00548-03
125E-5 Series
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points on troubleshooting..................................................................................................................... 2
Error code and failure code table ......................................................................................................... 4
Information in troubleshooting table ..................................................................................................... 8
125E-5 Series 1
SEN00548-03 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
2 125E-5 Series
40 Troubleshooting SEN00548-03
125E-5 Series 3
SEN00548-03 40 Troubleshooting
4 125E-5 Series
40 Troubleshooting SEN00548-03
125E-5 Series 5
SEN00548-03 40 Troubleshooting
(for Generator)
Machine failure Reference
Failure phenomenon
code document No.
A8 Speed Adj. Vol. High (Isochronous) A8
A9 Speed Adj. Vol. Low (Isochronous) A9
AA Speed Adj. Vol. High (Droop) AA
AB Speed Adj. Vol. Low (Droop) AB
AF KOMNET Error (CR710) AF
b6 Droop Rate Adj. Vol. High b6
b7 Droop Rate Adj. Vol. Low b7 —
b8 Low Idle Speed Adj. Vol. High b8
b9 Low Idle Speed Adj. Vol. Low b9
bc Speed Adj. Vol. High (Default) bc
bd Speed Adj. Vol. Low (Default) bd
bE Ramptime Adj. Vol. High bE
bF Ramptime Adj. Vol. Low bF
CA111 ECM Critical Internal Failure CA111
CA115 Ne, Bkup Speed Sensor Error CA115
CA122 Charge Air Press Sensor High CA122
CA123 Charge Air Press Sensor Low CA123
CA135 Oil Press. Sensor High CA135
CA141 Oil Press. Sensor Low CA141
CA144 Coolant Temp. Sensor High CA144
CA145 Coolant Temp. Sensor Low CA145
CA153 Charge Air Temp. Sensor High CA153
CA154 Charge Air Temp. Sensor Low CA154
CA187 Sensor Sup. 2 Volt. Low CA187
CA221 Ambient Air Press. Sensor High CA221
CA222 Ambient Air Press. Sensor Low CA222
CA227 Sensor Sup. 2 Volt. High CA227
CA234 Eng. Overspeed CA234 Troubleshooting of electrical
CA238 Ne Speed Sensor Sup. Volt. Error CA238 system (E-mode), Part 1
CA263 Fuel Temp. Sensor High CA263 SEN00550-01
6 125E-5 Series
40 Troubleshooting SEN00548-03
125E-5 Series 7
SEN00548-03 40 Troubleshooting
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source
2 (24 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are reference
state numbers, which do not indicate <Precautions for troubleshooting>
priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trou-
bleshooting, unless otherwise specified.
3
• If connector No. has no marks of “male“ and “female“,
disconnect connector and insert T-adapters in both
male side and female side.
• If connector No. has marks of “male“ and “female“,
disconnect connector and connect T-adapter to only
male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester
as explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or wiring harness
entered on rear side.
8 125E-5 Series
40 Troubleshooting SEN00548-03
125E-5 Series 9
SEN00548-03
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
10
SEN00550-01
125E-5 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure ............................................................................ 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 6
E-3 Code [122/CA122] Charge Air Press Sensor High Error ............................................................... 8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error.............................................................. 10
E-5 Code [131/CA131] Throttle Sensor High Error ............................................................................ 12
E-6 Code [132/CA132] Throttle Sensor Low Error............................................................................. 16
E-7 Code [135/CA135] Oil press. Sensor High Error ......................................................................... 18
E-8 Code [141/CA141] Oil press. Sensor Low Error.......................................................................... 20
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 22
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 24
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error........................................................... 26
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ........................................................... 28
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error..................................................................... 29
125E-5 Series 1
SEN00550-01 40 Troubleshooting
2 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 3
SEN00550-01 40 Troubleshooting
4 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 5
SEN00550-01 40 Troubleshooting
6 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 7
SEN00550-01 40 Troubleshooting
8 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 9
SEN00550-01 40 Troubleshooting
10 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 11
SEN00550-01 40 Troubleshooting
12 125E-5 Series
40 Troubleshooting SEN00550-01
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HM300-2)
125E-5 Series 13
SEN00550-01 40 Troubleshooting
14 125E-5 Series
40 Troubleshooting SEN00550-01
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)
125E-5 Series 15
SEN00550-01 40 Troubleshooting
16 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 17
SEN00550-01 40 Troubleshooting
18 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 19
SEN00550-01 40 Troubleshooting
20 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 21
SEN00550-01 40 Troubleshooting
22 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 23
SEN00550-01 40 Troubleshooting
24 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 25
SEN00550-01 40 Troubleshooting
26 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 27
SEN00550-01 40 Troubleshooting
28 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 29
SEN00550-01 40 Troubleshooting
30 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 31
SEN00550-01 40 Troubleshooting
32 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 33
SEN00550-01 40 Troubleshooting
34 125E-5 Series
40 Troubleshooting SEN00550-01
Remarks: The figure shows “with EGR” for an example. Following connectors apply to only “with EGR”.
Applied connector: BP, EGR, PEVA, SEGR, SBP
125E-5 Series 35
SEN00550-01 40 Troubleshooting
36 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 37
SEN00550-01 40 Troubleshooting
38 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 39
SEN00550-01 40 Troubleshooting
40 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 41
SEN00550-01 40 Troubleshooting
42 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 43
SEN00550-01 40 Troubleshooting
44 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 45
SEN00550-01 40 Troubleshooting
46 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 47
SEN00550-01 40 Troubleshooting
48 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 49
SEN00550-01 40 Troubleshooting
50 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 51
SEN00550-01 40 Troubleshooting
52 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 53
SEN00550-01 40 Troubleshooting
54 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 55
SEN00550-01 40 Troubleshooting
56 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 57
SEN00550-01 40 Troubleshooting
58 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 59
SEN00550-01 40 Troubleshooting
60 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 61
SEN00550-01 40 Troubleshooting
62 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 63
SEN00550-01 40 Troubleshooting
64 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 65
SEN00550-01 40 Troubleshooting
66 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 67
SEN00550-01 40 Troubleshooting
68 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 69
SEN00550-01 40 Troubleshooting
70 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 71
SEN00550-01 40 Troubleshooting
72 125E-5 Series
40 Troubleshooting SEN00550-01
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal 5 Defective engine controller E02 Signal name Voltage
state Between (11) – (32) Signal 1
See Fig. 1
Between (1) – (32) Signal 2
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HM300-2)
Fig. 1
125E-5 Series 73
SEN00550-01 40 Troubleshooting
74 125E-5 Series
40 Troubleshooting SEN00550-01
125E-5 Series 75
SEN00550-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)
76
SEN00551-01
125E-5 Series
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
E-39 Code [449/CA449] Rail Press. Very High Error ........................................................................... 3
E-40 Code [451/CA451] Rail Press. Sensor High Error ....................................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error........................................................................ 6
E-42 Code [553/CA553] Rail Press. High Error ................................................................................... 6
E-43 Code [554/CA554] Rail Press Sensor In Range Error................................................................. 7
E-44 Code [559/CA559] Rail Press. Low Error .................................................................................... 8
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 12
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 14
E-47 Code [757/CA757] All Persistent Data Lost Error...................................................................... 15
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 16
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 18
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 19
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error ............................................. 20
125E-5 Series 1
SEN00551-01 40 Troubleshooting
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error .............................................. 22
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 .................................................................... 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 .................................................................... 24
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error................................................. 26
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ................................................. 28
E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error ............................................................ 28
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error ......................................................... 29
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error......................................................... 30
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 32
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 36
E-62 Code [2249/CA2249] Rail Press. Very Low Error ...................................................................... 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error ............................................. 38
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error .............................................. 40
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error ................................................. 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error .................................................. 44
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error........................................................... 45
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error .......................................................... 46
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate.............................................................. 48
E-70 Code [(146)/B@BCNS] Eng. Overheat...................................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate....................................................... 49
2 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 3
SEN00551-01 40 Troubleshooting
4 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 5
SEN00551-01 40 Troubleshooting
6 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 7
SEN00551-01 40 Troubleshooting
8 125E-5 Series
40 Troubleshooting SEN00551-01
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
125E-5 Series 9
SEN00551-01 40 Troubleshooting
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating <By models> mm3 — — —
4 Common rail pressure
*4 Equivalent to rating <By models> MPa
command
Common rail fuel
*5 Equivalent to rating <By models> MPa
pressure
Low idle CA — — —
Fuel injection timing
*6 High idle CA — — —
command
Equivalent to rating <By models> CA — — —
*7 Boost pressure Equivalent to rating <By models> kPa — — —
Engine coolant
*8 Low idle °C — — —
temperature
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
No. 1 cylinder Low idle rpm — — —
5 No. 2 cylinder Low idle rpm — — —
No. 3 cylinder Low idle rpm — — —
*10
No. 4 cylinder Low idle rpm — — —
No. 5 cylinder Low idle rpm — — —
No. 6 cylinder Low idle rpm — — —
10 125E-5 Series
40 Troubleshooting SEN00551-01
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
125E-5 Series 11
SEN00551-01 40 Troubleshooting
12 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 13
SEN00551-01 40 Troubleshooting
14 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 15
SEN00551-01 40 Troubleshooting
16 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 17
SEN00551-01 40 Troubleshooting
18 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 19
SEN00551-01 40 Troubleshooting
20 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 21
SEN00551-01 40 Troubleshooting
22 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 23
SEN00551-01 40 Troubleshooting
24 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 25
SEN00551-01 40 Troubleshooting
26 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 27
SEN00551-01 40 Troubleshooting
28 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 29
SEN00551-01 40 Troubleshooting
30 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 31
SEN00551-01 40 Troubleshooting
32 125E-5 Series
40 Troubleshooting SEN00551-01
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HM300-2)
125E-5 Series 33
SEN00551-01 40 Troubleshooting
34 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 35
SEN00551-01 40 Troubleshooting
36 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 37
SEN00551-01 40 Troubleshooting
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error 1
a This code applies to only “with EGR”.
Error code Failure code
Trouble EGR Valve Lift Position Sensor High Error
2271 CA2271
Contents of
• Signal voltage in EGR valve lift sensor circuit is abnormally high.
trouble
Action of • Limits output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
appears on • Output drops.
machine
Related
• Different machine models may have different connector Nos.
information
38 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 39
SEN00551-01 40 Troubleshooting
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error 1
a This code applies to only “with EGR”.
Error code Failure code
Trouble EGR Valve Lift Position Sensor Low Error
2272 CA2272
Contents of
• Signal voltage in EGR valve lift sensor circuit is abnormally low.
trouble
Action of • Limits output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
appears on • Output drops.
machine
Related
information
40 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 41
SEN00551-01 40 Troubleshooting
42 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 43
SEN00551-01 40 Troubleshooting
44 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 45
SEN00551-01 40 Troubleshooting
46 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 47
SEN00551-01 40 Troubleshooting
48 125E-5 Series
40 Troubleshooting SEN00551-01
125E-5 Series 49
SEN00551-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)
50
SEN00549-02
125E-5 Series
40 Troubleshooting 1
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 4
Method of using troubleshooting charts ............................................................................................... 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start................................................................................................................... 10
S-3 Engine does not pick up smoothly............................................................................................... 14
S-4 Engine stops during operations ................................................................................................... 15
S-5 Engine does not rotate smoothly ................................................................................................. 16
S-6 Engine lacks output (or lacks power)........................................................................................... 17
S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 20
S-9 Oil becomes contaminated quickly .............................................................................................. 21
S-10 Fuel consumption is excessive.................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 23
S-12 Oil pressure drops ..................................................................................................................... 24
125E-5 Series 1
SEN00549-02 40 Troubleshooting
2 125E-5 Series
40 Troubleshooting SEN00549-02
125E-5 Series 3
SEN00549-02 40 Troubleshooting
Questions:
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items:
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the
right.
Causes:
Items to be narrowed from the questions and check items.
The serviceman narrows down the probable causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable
one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the “causes”, do not apply the items marked with E (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 125E-5 Series
40 Troubleshooting SEN00549-02
125E-5 Series 5
SEN00549-02 40 Troubleshooting
6 125E-5 Series
40 Troubleshooting SEN00549-02
6 items of [causes] have causal relationship with these 3 items of [questions] and [check items].
Let us explain the method of using this causal relationship in “Step 1” to “Step 3” in the figure below to narrow
the [causes] to lead to [troubleshooting].
125E-5 Series 7
SEN00549-02 40 Troubleshooting
Defective injector
not start until the crankshaft revolves 2 turns at maxi-
mum. This phenomenon does not indicate a trouble,
however.
When a cylinder is cut out for reduced cylinder mode operation, engine speed q
does not change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 125E-5 Series
40 Troubleshooting SEN00549-02
125E-5 Series 9
SEN00549-02 40 Troubleshooting
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1)
["with EGR" only]. q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
There is not voltage (20 – 30 V) between battery relay terminal q
B and terminal E
When terminal B and terminal C of starting switch are con-
Turn starting switch OFF, q
nected, engine starts
connect cord, and carry out
troubleshooting at ON When terminal B and terminal C at safety relay outlet are con-
nected, engine starts q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
10 125E-5 Series
40 Troubleshooting SEN00549-02
125E-5 Series 11
SEN00549-02 40 Troubleshooting
Degree of use of
machine Operated for long period E E E
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Add
Remedy
12 125E-5 Series
40 Troubleshooting SEN00549-02
c) Exhaust smoke comes out but engine does not start Causes
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow Q w w
cranked with starting out
motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of w
some cylinders is low
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
125E-5 Series 13
SEN00549-02 40 Troubleshooting
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
applied Q w w
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in
E-mode
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
14 125E-5 Series
40 Troubleshooting SEN00549-02
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy —
125E-5 Series 15
SEN00549-02 40 Troubleshooting
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)” in E-mode q
["with EGR" only]
Carry out troubleshooting according to “Abnormality in bypass valve servo (*2)” in E-
q
mode ["with EGR" only]
Troubleshooting
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Add
Remedy
16 125E-5 Series
40 Troubleshooting SEN00549-02
(air leakage)
Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
125E-5 Series 17
SEN00549-02 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
18 125E-5 Series
40 Troubleshooting SEN00549-02
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-
mode
*2: EGR gas piping
Remove EGR gas piping (1) and confirm for internal clogging
125E-5 Series 19
SEN00549-02 40 Troubleshooting
Turbocharger
q Abnormal consumption of oil
When EGR valve is removed, exhaust port is found to be dirty with oil ["with
q
EGR" only]
Inspect breather and breather hose directly q
When compression pressure is measured, it is found to be low q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 125E-5 Series
40 Troubleshooting SEN00549-02
See S-7.
Inspect breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy —
125E-5 Series 21
SEN00549-02 40 Troubleshooting
Correct
Correct
Remedy
22 125E-5 Series
40 Troubleshooting SEN00549-02
S-11 Oil is in coolant (or coolant spurts back or coolant level goes
down) 1
General causes why oil is in coolant Causes
Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check
items
Remedy —
125E-5 Series 23
SEN00549-02 40 Troubleshooting
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
w
nance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q Q Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
w w
Check items
Valve and spring of oil pump relief valve are fatigued, damaged q
See SI13.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Add
Remedy —
24 125E-5 Series
40 Troubleshooting SEN00549-02
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1) q
[with EGR only]
When compression pressure is measured, it is found to be low q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
125E-5 Series 25
SEN00549-02 40 Troubleshooting
26 125E-5 Series
40 Troubleshooting SEN00549-02
machine side
Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Questions
Suddenly overheated Q Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Coolant temperature gauge Rises quickly Q w
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is
installed) Q w
q
Carry out troubleshooting
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Add
Remedy —
125E-5 Series 27
SEN00549-02 40 Troubleshooting
Gradually occurred Q Q
Abnormal noise
Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around EGR gas piping
w
["with EGR" only]
When engine is cranked, abnormal sound is generated around cylinder head w w
w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
28 125E-5 Series
40 Troubleshooting SEN00549-02
Replace
Replace
Adjust
Remedy
125E-5 Series 29
SEN00549-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
30
SEN00697-03
125E-5 Series
125E-5 Series 1
SEN00697-03 50 Disassembly and assembly
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each Installation
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
2 125E-5 Series
50 Disassembly and assembly SEN00697-03
125E-5 Series 3
SEN00697-03 50 Disassembly and assembly
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 125E-5 Series
50 Disassembly and assembly SEN00697-03
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
Seizure
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
125E-5 Series 5
SEN00697-03 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
6 125E-5 Series
50 Disassembly and assembly SEN00697-03
New / Remodel
Necessity
Sketch
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
125E-5 Series 7
SEN00697-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
8
SEN00698-02
125E-5 Series
125E-5 Series 1
SEN00698-02 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its parts
for cracking, damage, etc. and clean it generally
and carefully for accurate inspection of its parts
and quick disassembly and assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
6. Alternator
2. Setting engine assembly 1) Remove cover (1).
1) Set the engine assembly (1) on rigid and 2) Loosen alternator mounting bolt (2) and
stable stands [1]. lock bolt (3).
a The weight depends on the applica- 3) Loosen locknut (4) and then loosen the
ble machines.
4 Engine assembly: 1,300 kg
belt tension using the tension adjustment
nut and remove V-belt.
4) Remove mounting bolt (2) and lock bolt
(3) and then remove alternator (5).
3. Harness assembly
Disconnect the connector and clamp and
remove the harness assembly.
5. Starting motor
Remove mounting bolt (1) and remove starting
motor (2).
2 125E-5 Series
50 Disassembly and assembly SEN00698-02
8. EGR cooler
1) Remove turbocharger drain tube (1).
2) Remove exhaust gas discharge tube (2).
3) Remove coolant tube (3).
4) Remove 2 air vent tubes (4).
5) Loosen rubber hose (5) clamp and then
remove the bolt on the water pump side
and remove tube (6).
125E-5 Series 3
SEN00698-02 50 Disassembly and assembly
11. Oil filter and oil tube assembly 13. Fuel tube
1) Remove the oil tube (1) block side mount- Remove clamp (3) and remove fuel tubes (1)
ing bolt. and (2).
2) Remove 4 mounting bolts on the oil filter
head side and remove oil filter and oil tube
assembly (2).
4 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 5
SEN00698-02 50 Disassembly and assembly
20. Diffuser and air housing assembly 21. Air intake manifold
1) Remove brackets (1) and (2) and then 1) Remove bracket (1).
remove oil filler (3).
2) Remove mounting bolt (4) at flanged por-
tion of the air housing. Remove the bolt
through the bottom.
6 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 7
SEN00698-02 50 Disassembly and assembly
25. Common rail and overflow tube 2) Remove the mounting bolt and then
1) Remove common rail (1). remove oil cooler assembly (4) using
2) Remove spill tube (2), overflow tube (3) guide bolt [1].
and block (4).
8 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 9
SEN00698-02 50 Disassembly and assembly
10 125E-5 Series
50 Disassembly and assembly SEN00698-02
42. Disassembly of cylinder head assembly 43. Setting to engine repair stand
1) Using tool C, compress valve spring (3) Lift the engine and then align currently installed
and remove valve cotter (4). tools A2 and A1 to set the engine.
2) Remove upper seat (5) and valve spring (3).
125E-5 Series 11
SEN00698-02 50 Disassembly and assembly
46. Flywheel
1) Using slings [1], lift up flywheel (1) tempo-
rarily.
2) Remove 6 mounting bolts to remove the
flywheel from the dowel pin and then lift off
the flywheel.
4 Flywheel: 25 kg
12 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 13
SEN00698-02 50 Disassembly and assembly
14 125E-5 Series
50 Disassembly and assembly SEN00698-02
57. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.
3) Lift off crankshaft (4).
a When removing the crankshaft, take
care so that its sliding surfaces may
not be damaged.
4 Crankshaft: 110 kg
125E-5 Series 15
SEN00698-02 50 Disassembly and assembly
16 125E-5 Series
50 Disassembly and assembly SEN00698-02
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 320 kg 2. Cylinder liner
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened
because of rusting or pitting. If those parts
are roughened, replace the cylinder liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Replace the O-ring and clevis seal
with new ones.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
2) Before inserting the cylinder liners, pre- refer to the following.
pare the cylinder block according to the q O-ring (2): The whole ring is black.
following procedure. q O-ring (3): The whole ring is red.
1] Remove the rust and scales from faces 2 Clevis seal and O-ring:
(A) and (B) with sandpaper, etc. until Rubber lubricant (LH-50 from NOF
the machined surfaces are exposed. Corporation)
125E-5 Series 17
SEN00698-02 50 Disassembly and assembly
a If LH-50 is not available, apply clean 4) Apply gasket sealant to the parts of the
engine oil SAE No. 30. cylinder block and cylinder liner which will
a Since the clevis seal and O-ring are fit to the counterboared parts.
swollen and deteriorated by oil, apply a Wipe off dirt and oil with cloth from
a small amount of oil to them thinly the contact faces of the counter-
with a brush just before fitting them. boared parts of the cylinder block and
liner flange.
2 Cylinder block: Gasket sealant (LG-6)
q Gasket sealant:
0.8 – 1.6 mm in diameter
q Overlap (a) of gasket sealant: 6 ± 6 mm
a If the applied gasket sealant is left for a
long time, its surface becomes hard.
Accordingly, install the cylinder block to
the cylinder head within 50 minutes.
18 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 19
SEN00698-02 50 Disassembly and assembly
4) Lift and set crankshaft (4) to the mounting 6) Install main cap (1).
position. a When installing, make sure that the
a When installing the crankshaft, take stamped No. at center of the main
care not to damage its sliding sur- cap is aligned to the stamped journal
faces by, for instance, bumping No. of the cylinder block.
against the cylinder block. a Install the main cap with the cast let-
a When replacing the crank gear, heat it ter (F) toward the front of the engine.
with a bearing heater set at 150°C 2 Crankshaft journal surface:
and then fit it immediately after the Engine oil (EO30)
heating.
4 Crankshaft: 110 kg
2 Cylinder block journal:
Engine oil (EO30)
8)
Screw in main cap mounting bolts (2)
alternately until the main cap (1) is
securely fitted in its place.
9) Tighten main cap mounting bolts (2)
according to the following procedure.
a Tighten the bolts from the center one
to the outer ones in order.
2 Threaded portion of mounting bolt and washer:
Engine oil (EO30)
20 125E-5 Series
50 Disassembly and assembly SEN00698-02
3 Mounting bolt
1st time : 98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd time : 196.1 ± 4.9 Nm {20 ± 0.5 kgm}
3rd time : Using tool J, tighten the bolt by
90° (+30°/0).
125E-5 Series 21
SEN00698-02 50 Disassembly and assembly
3) Install snap ring (4) to one side of piston (7). 7) Install upper main bearing (8) to the notch
4) Heat piston (7) at 100°C for 5 minutes of the connecting rod while aligning the
minimum in the heating furnace. bearing projection to it.
a When the furnace is not available, a Before fitting the bearing, check that its
heat it at 100°C for 5 minutes mini- back side is free from foreign matter.
mum in hot water. a Make sure that the bearing hole and
connecting rod oil hole are aligned.
22 125E-5 Series
50 Disassembly and assembly SEN00698-02
9) Set the cylinder crankshaft, to which the pis- 12) Install connecting rod cap (2).
ton and connecting rod assembly is to be a Align match mark of connecting rod
assembled, to the bottom dead center. (5 ) and connecting ro d cap (2).
10) Insert piston and connecting rod assembly (Above aligns the match mark to ID
(3) in the cylinder block so that ID marking marking "6251" on the opposite side.)
"6251" of the connecting rod may be faced 2 Inner surface of connecting rod cap
toward the left side face of the engine. bearing: Engine oil (EO30)
a Make sure the abutment joint of the
piston ring is located in the position
indicated in the following figure.
2 Inner surface of connecting rod and
cylinder: Engine oil (EO30)
125E-5 Series 23
SEN00698-02 50 Disassembly and assembly
24 125E-5 Series
50 Disassembly and assembly SEN00698-02
8. Oil pump
1) Install oil pump (2) after attaching the O-
ring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).
7. Idler gear
1) Install plate (8) to the engine block and then
install main idler gear (7) and shaft (6).
a When installing plate (8), set its
chamfered side to the front side of the
engine.
2) Matching “A” mark of the crankshaft gear
and “A” mark of main idler gear (7),
tighten mounting bolt (5).
3 Mounting bolt:
245 – 294 Nm {25 – 30 kgm}
125E-5 Series 25
SEN00698-02 50 Disassembly and assembly
a Rotate the camshaft when assem- 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
bling so that the cam bushing may not 2) Install brackets (3), oil tube (2) and oil
be damaged. level gauge (1).
a When replacing the cam gear, heat it
at 200 – 240°C for 30 minutes mini-
mum in an electronic oven and then
shrink fit it.
2 Camshaft journal surface:
Engine oil (EO30)
2) Matching “B” mark of the crankshaft gear
and “B” mark of the main idler gear,
tighten mounting bolt (1).
26 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 27
SEN00698-02 50 Disassembly and assembly
28 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 29
SEN00698-02 50 Disassembly and assembly
5) Using dial gauge [3], measure the level a Never remove inside plastic cylinder
difference between underside faces of the (3) of the standard spare seal before
cylinder block and flywheel housing. installing the seal.
a Difference: 0 – 0.35 mm 1) Set the large inside diameter side (b)
a If the difference is out of the standard, of plastic inside cylinder (3) to the end
correct it. For details, see “Structure, of crankshaft (4).
function and maintenance standard”. a Take care not to mistake the direc-
tion of the plastic inside cylinder.
30 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 31
SEN00698-02 50 Disassembly and assembly
21. Flywheel
1) Using sling [1], lift up flywheel (1) and then
install it aligning to the dowel pin.
2) Tighten mounting bolts (2) in the following
order in 2 steps.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt
1st time:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
32 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 33
SEN00698-02 50 Disassembly and assembly
34 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 35
SEN00698-02 50 Disassembly and assembly
36 125E-5 Series
50 Disassembly and assembly SEN00698-02
33. Injector 4) Fit the ball washer to bolt (3) and tighten
a Check that the inside of the injector sleeve holder (2) temporarily.
is free from dirt. 2 Spherical part of washer:
1) Install common rail (9) temporarily. Engine oil (EO30)
5) Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them tem-
porarily.
a Tighten the common rail side sleeve
nut temporarily, too.
6) Tighten holder (2) with bolt (3) perma-
nently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the oppo-
site direction of the injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
7) After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
2) Install gasket (6) and O-rings (7) and (8) to injectors in order according to the above
injector (1).
2 O-ring: Engine oil (EO30)
procedure.
8) Remove the temporarily installed common
rail.
125E-5 Series 37
SEN00698-02 50 Disassembly and assembly
35. Rocker arm and shaft assembly 37. Adjusting valve clearance
1) Set rocker arm and shaft assembly (1). a Adjust the clearance between the cross-
a When installing the rocker arm shaft, head and rocker arm to the following
be sure to set its side with a larger value.
mounting hole diameter to the bottom a Valve clearance (in cold state)
and to direct ball plug (6) side toward
Unit: mm
the front side of the engine.
2) Before tightening mounting bolts (4), Intake valve Exhaust valve
check that the ball of adjustment screw (2) 0.33 0.71
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning a Rotate the engine and adjust the valve
its oil hole. clearance of each cylinder in the firing
3 Mounting bolt: order of 1 – 5 – 3 – 6 – 2 – 4.
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 1) Rotate the crankshaft forward and match
stamped line of “1.6 TOP” on vibration
damper (1) to pointer (2), watching the
movement of the valve.
38 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 39
SEN00698-02 50 Disassembly and assembly
40 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 41
SEN00698-02 50 Disassembly and assembly
42 125E-5 Series
50 Disassembly and assembly SEN00698-02
1) Install high-pressure pipes (3), (4), (5), (6), 5) Install bracket (17).
(7) and (8). 3 Clamp tightening torque:
a Mounting angle of the high-pressure 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
injection pipe is adjusted before the 6) Tighten clamps (11), (12), (13), and (14)
installation of the injector. permanently.
3 Sleeve nut (on both sides): 3 Mounting bolt:
39.2 – 49 Nm {4 – 5 kgm} 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2) Tighten bracket (9) and clamp (10) by
hand first, and then tighten them perma-
nently.
3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3) Install clamps (11), (12), (13) and (14) by
tightening them by hand.
4) Install 6 each of the splash prevention
covers (15) and (16).
Direct the slit on the injector side down-
ward and that on the common rail side
toward the cylinder block.
125E-5 Series 43
SEN00698-02 50 Disassembly and assembly
44 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 45
SEN00698-02 50 Disassembly and assembly
46 125E-5 Series
50 Disassembly and assembly SEN00698-02
125E-5 Series 47
SEN00698-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
48
SEN00699-03
125E-5 Series
125E-5 Series 1
SEN00699-03 50 Disassembly and assembly
1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
2 125E-5 Series
50 Disassembly and assembly SEN00699-03
6. Alternator assembly
1) Remove cover (1).
2) Loosen alternator mounting bolt (2) and
fixing bolt (3).
3) Remove nut (4), loosen the locknut, lower
the belt tension with the tension adjust-
ment nut, and remove V-belt (5).
4) Remove mounting bolt (2), fixing bolt (3)
and alternator assembly (6).
5) Remove plate (7) and bracket (8).
a These parts depend on each applicable
machine.
8. Turbocharger assembly
1) Remove bracket (1).
2) Remove the 5 clamps and turbocharger
lubricating oil inlet tube (2).
3) Remove the tube bracket and turbo-
charger outlet tube (3).
4) Remove 4 mounting bolts (4) and turbo-
charger assembly (5).
125E-5 Series 3
SEN00699-03 50 Disassembly and assembly
15. Brackets
Remove brackets (1), (2), (3), (4), (5), (6) and
(7).
4 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 5
SEN00699-03 50 Disassembly and assembly
6 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 7
SEN00699-03 50 Disassembly and assembly
4) Remove pump mounting bolts (6) and 28. Injector wiring harness
bracket (7). 1) Fully loosen 2 wiring harness terminal
a Leave bolts (6) tightened by 2 – 3 mounting nuts (2) on the head of injector
threads to prevent the pump from fall- (1).
ing down. a Loosen nuts alternately.
5) Install tool P1 with P2 and P3 and then 2) Loosen bolt (3) of harness fixing holder.
screw in the center bolt of P1 to remove
the gear from the shaft.
6) Remove remaining bolts and then remove
fuel supply pump assembly (8).
a Leave tools P1, P2 and P3 in the
installed condition.
8 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 9
SEN00699-03 50 Disassembly and assembly
10 125E-5 Series
50 Disassembly and assembly SEN00699-03
42. Flywheel
1) Install sling [1] to flywheel (1) and lift it up.
2) Remove the 6 mounting bolts, remove the
flywheel from the dowel pins, and lift it off.
4 Flywheel: 25 kg
125E-5 Series 11
SEN00699-03 50 Disassembly and assembly
46. Camshaft
1) Remove 2 mounting bolts (1).
2) Remove camshaft (2).
a When pulling out the camshaft, turn it
gently so that damages may not be
left on the cam bushing.
12 125E-5 Series
50 Disassembly and assembly SEN00699-03
49. Oil suction pipe 51. Piston and connecting rod assembly
Remove brackets (1) and then remove oil suc- a Before removing the piston and connect-
tion pipe (2). ing rod assembly, measure its end play
with dial gauge [3], if necessary.
125E-5 Series 13
SEN00699-03 50 Disassembly and assembly
6) Push in and remove the piston and con- 3] Using tool D, remove piston ring (8).
necting rod assembly with a wood bar, etc. a Keep the piston, connecting rod,
from the oil pan side, while supporting pis- connecting rod bearing, piston
ton (3) on the cylinder head side. rings, and piston pin by each cyl-
a Take care not to damage the inside of inder.
the cylinder with a corner of the con-
necting rod.
7) Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.
52. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.
14 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 15
SEN00699-03 50 Disassembly and assembly
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 320 kg 2. Cylinder liner
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened
because of rusting or pitting. If those parts
are roughened, replace the cylinder liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Replace the O-ring and clevis seal
with new ones.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
2) Before inserting the cylinder liners, pre- refer to the following.
pare the cylinder block according to the q O-ring (2): The whole ring is black.
following procedure. q O-ring (3): The whole ring is red.
1] Remove the rust and scales from faces 2 Clevis seal and O-ring:
(A) and (B) with sandpaper, etc. until Rubber lubricant (LH-50 from NOF
the machined surfaces are exposed. Corporation)
16 125E-5 Series
50 Disassembly and assembly SEN00699-03
a If LH-50 is not available, apply clean 4) Apply gasket sealant to the parts of the
engine oil SAE No. 30. cylinder block and cylinder liner which will
a Since the clevis seal and O-ring are fit to the counterboared parts.
swollen and deteriorated by oil, apply a Wipe off dirt and oil with cloth from
a small amount of oil to them thinly the contact faces of the counter-
with a brush just before fitting them. boared parts of the cylinder block and
liner flange.
2 Cylinder block: Gasket sealant (LG-6)
q Gasket sealant:
0.8 – 1.6 mm in diameter
q Overlap (a) of gasket sealant: 6 ± 6 mm
a If the applied gasket sealant is left for a
long time, its surface becomes hard.
Accordingly, install the cylinder block to
the cylinder head within 50 minutes.
125E-5 Series 17
SEN00699-03 50 Disassembly and assembly
18 125E-5 Series
50 Disassembly and assembly SEN00699-03
4) Lift and set crankshaft (4) to the mounting 6) Install main cap (1).
position. a When installing, make sure that the
a When installing the crankshaft, take stamped No. at center of the main
care not to damage its sliding sur- cap is aligned to the stamped journal
faces by, for in stance, bumping No. of the cylinder block.
against the cylinder block. a Install the main cap with the cast let-
a When replacing the crank gear, heat it ter (F) toward the front of the engine.
with a bearing heater set at 150°C 2 Crankshaft journal surface:
and then fit it immediately after the Engine oil (EO30-DH)
heating.
4 Crankshaft: 110 kg
2 Cylinder block journal:
Engine oil (EO30-DH)
8)
Screw in main cap mounting bolts (2)
alternately until the main cap (1) is
securely fitted in its place.
9) Tighten main cap mounting bolts (2)
according to the following procedure.
a Tighten the bolts from the center one
to the outer ones in order.
2 Threaded portion of mounting bolt and washer:
Engine oil (EO30-DH)
125E-5 Series 19
SEN00699-03 50 Disassembly and assembly
3 Mounting bolt
1st time : 98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd time : 196.1 ± 4.9 Nm {20 ± 0.5 kgm}
3rd time : Using tool J, tighten the bolt by
90° (+30°/0).
20 125E-5 Series
50 Disassembly and assembly SEN00699-03
3) Install snap ring (4) to one side of piston (7). 7) Install upper main bearing (8) to the notch
4) Heat piston (7) at 100°C for 5 minutes of the connecting rod while aligning the
minimum in the heating furnace. bearing projection to it.
a When the furnace is not available, a Before fitting the bearing, check that its
heat it at 100°C for 5 minutes mini- back side is free from foreign matter.
mum in hot water. a Make sure that the bearing hole and
connecting rod oil hole are aligned.
125E-5 Series 21
SEN00699-03 50 Disassembly and assembly
9) Set the cylinder crankshaft, to which the pis- 12) Install connecting rod cap (2).
ton and connecting rod assembly is to be a Align match mark of connecting rod
assembled, to the bottom dead center. (5 ) and connecting ro d cap (2).
10) Insert piston and connecting rod assembly (Above aligns the match mark to ID
(3) in the cylinder block so that ID marking marking "6251" on the opposite side.)
"6251" of the connecting rod may be faced 2 Inner surface of connecting rod cap
toward the left side face of the engine. bearing: Engine oil (EO30-DH)
a Make sure the abutment joint of the
piston ring is located in the position
indicated in the following figure.
2 Inner surface of connecting rod and
cylinder: Engine oil (EO30-DH)
22 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 23
SEN00699-03 50 Disassembly and assembly
8. Oil pump
1) Install oil pump (2) after attaching the O-
ring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).
7. Idler gear
1) Install plate (8) to the engine block and then
install main idler gear (7) and shaft (6).
a When installing plate (8), set its
chamfered side to the front side of the
engine.
2) Matching “A” mark of the crankshaft gear
and “A” mark of main idler gear (7),
tighten mounting bolt (5).
3 Mounting bolt:
245 – 294 Nm {25 – 30 kgm}
24 125E-5 Series
50 Disassembly and assembly SEN00699-03
a Rotate the camshaft when assem- 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
bling so that the cam bushing may not
be damaged.
a When replacing the cam gear, heat it
at 200 – 240°C for 30 minutes mini-
mum in an electronic oven and then
shrink fit it.
2 Camshaft journal surface:
Engine oil (EO30-DH)
2) Matching “B” mark of the crankshaft gear
and “B” mark of the main idler gear,
tighten mounting bolt (1).
125E-5 Series 25
SEN00699-03 50 Disassembly and assembly
14. Fuel supply pump assembly 15. Make sure that match marks (A to C) of drive
1) Set fuel supply pump assembly (3) and gears and idler gears are matched.
then tighten it temporarily using 4 mount-
ing bolts (5).
a Tighten it permanently according to
Step 39. described below.
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning “C” mark to
“C” mark of camshaft gear (2) while align-
ing the key groove of supply pump drive
gear (1) to the woodruff key of the shaft.
3) Fit the washer and then tighten them
using gear mounting nut (4).
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm}
4) Install bracket (6).
3 Mounting bolt (supply pump side):
19.6 – 29.4 Nm {2.0 – 3.0 kgm} 16. Measuring backlash and end play
a Leave the cylinder block side mount- a Measure the backlash and end play of
ing bolt in temporarily tightened state each gear with dial gauge [3].
(it is to be tightened permanently in
the following Step 39.). • Standard backlash of each gear
Position Range (mm)
a 0.105 – 0.325
b 0.105 – 0.325
c 0.116 – 0.359
d 0.105 – 0.337
e 0.082 – 0.389
f 0.076 – 0.366
26 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 27
SEN00699-03 50 Disassembly and assembly
28 125E-5 Series
50 Disassembly and assembly SEN00699-03
5) Using dial gauge [3], measure the level a Never remove inside plastic cylinder
difference between underside faces of the (3) of the standard spare seal before
cylinder block and flywheel housing. installing the seal.
a Difference: 0 – 0.35 mm 1) Set the large inside diameter side (b)
a If the difference is out of the standard, of plastic inside cylinder (3) to the end
correct it. For details, see “Structure, of crankshaft (4).
function and maintenance standard”. a Take care not to mistake the direc-
tion of the plastic inside cylinder.
125E-5 Series 29
SEN00699-03 50 Disassembly and assembly
30 125E-5 Series
50 Disassembly and assembly SEN00699-03
20. Flywheel
1) Using sling [1], lift up flywheel (1) and then
install it aligning to the dowel pin.
2) Tighten mounting bolts (2) in the following
order in 2 steps.
2 Mounting bolt: Engine oil (EO30-
DH)
3 Mounting bolt
1st time:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
125E-5 Series 31
SEN00699-03 50 Disassembly and assembly
32 125E-5 Series
50 Disassembly and assembly SEN00699-03
26. Assembly of cylinder head assembly 27. Installation of cylinder head assembly
1) Assemble valve (6). 1) Check that the cylinder head mounting
2 Valve stem: Engine oil (EO30-DH) face and inside of the cylinder are free
2) Raise the cylinder head and then install from foreign matter and then set cylinder
lower seat (8) and seal (7). head gasket (1).
a When fitting the gasket, check that
the grommets are fitted correctly.
125E-5 Series 33
SEN00699-03 50 Disassembly and assembly
34 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 35
SEN00699-03 50 Disassembly and assembly
31. Injector 4) Fit the ball washer to bolt (3) and tighten
a Check that the inside of the injector sleeve holder (2) temporarily.
is free from dirt. 2 Spherical part of washer:
1) Fit bracket (5) and install common rail (6) Engine oil (EO30-DH)
temporarily. 5) Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them tem-
porarily.
a Tighten the common rail side sleeve
nut temporarily, too.
6) Tighten holder (2) with bolt (3) perma-
nently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the oppo-
site direction of the injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
7) After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
2) Install gasket (6) and O-rings (7) and (8) to injectors in order according to the above
injector (1). procedure.
2 O-ring: Engine oil (EO30-DH) 8) Remove the temporarily installed common
rail.
36 125E-5 Series
50 Disassembly and assembly SEN00699-03
33. Rocker arm and shaft assembly 35. Adjusting valve clearance
1) Set rocker arm and shaft assembly (1). a Adjust the clearance between the cross-
a When installing the rocker arm shaft, head and rocker arm to the following
be sure to set its side with a larger value.
mounting hole diameter to the bottom a Valve clearance (in cold state)
and to direct ball plug (6) side toward
Unit: mm
the front side of the engine.
2) Before tightening mounting bolts (4), Intake valve Exhaust valve
check that the ball of adjustment screw (2) 0.33 0.71
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning a Rotate the engine and adjust the valve
its oil hole. clearance of each cylinder in the firing
3 Mounting bolt: order of 1 – 5 – 3 – 6 – 2 – 4.
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 1) Rotate the crankshaft forward and match
stamped line of “1.6 TOP” on vibration
damper (1) to pointer (2), watching the
movement of the valve.
125E-5 Series 37
SEN00699-03 50 Disassembly and assembly
38 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 39
SEN00699-03 50 Disassembly and assembly
40 125E-5 Series
50 Disassembly and assembly SEN00699-03
5) Install bracket (2) and tighten the 2 mount- 44. Diffuser and air housing assembly
ing bolts. Fit the gasket and install diffuser and air hous-
6) Tighten 7 high-pressure pipe clamp ing assembly temporarily.
mounting bolts (1). 4 Diffuser and air housing assembly: 40 kg
3 Clamp mounting bolt:
a Fix the front hanger first and then tighten
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
the mounting bolts permanently.
43. Bracket
1) Install bracket (2).
2) Install bracket (1).
125E-5 Series 41
SEN00699-03 50 Disassembly and assembly
46. Brackets
1) Install brackets (3) and (2).
2) Install wiring harness (1).
42 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 43
SEN00699-03 50 Disassembly and assembly
4
44.1 – 49 Nm {4.5 – 5.0 kgm}
Exhaust manifold assembly: 35 kg
2) Fit the gasket and install turbocharger out-
let tube (4) and tube bracket.
3) Fit the gasket and install turbocharger
lubricating oil inlet tube (3) and 5 clamps.
3 Sleeve nut (Cylinder block side):
40 – 44 Nm {4.1 – 4.5 kgm}
4) Install brackets (2) and (1).
44 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 45
SEN00699-03 50 Disassembly and assembly
62. Tightening torque for sensor 5) Check the fuel piping and devices for fuel
Use the following tightening torque when leakage.
removal and installation or replacement of the a Check mainly around the high-pres-
sensor. sure circuit parts coated with the color
checker for fuel leakage.
Sensor name Tightening torque
a If any fuel leakage is detected, repair
Fuel it and check again from step 2).
23 ± 3 Nm {2.35 ± 0.3 kgm}
temperature 6) Run the engine at high idle.
Boost pressure 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm} 7) Check the fuel piping and devices for fuel
Intake air leakage.
23 ± 3 Nm {2.35 ± 0.3 kgm} a Check mainly around the high-pres-
temperature
Coolant sure circuit parts coated with the color
23 ± 3 Nm {2.35 ± 0.3 kgm} checker for fuel leakage.
temperature
a If any fuel leakage is detected, repair
Engine oil
23 ± 3 Nm {2.35 ± 0.3 kgm} it and check again from step 2).
pressure
8) Run the engine at high idle and load it.
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm} a When checking while the components
Atmospheric
(Hexagonal head bolt and hexago-
pressure to be checked are mounted on the
nal socket head bolt)
machine, stall the torque converter or
Fuel pressure Never disassemble. relieve the hydraulic pump.
9) Check the fuel piping and devices for fuel
leakage.
63. Checking for fuel leakage a Check mainly around the high-pres-
a If fuel supply pump (2), common rail (1), or sure circuit parts coated with the color
high-pressure pipe is removed and checker for fuel leakage.
installed, after assembling the engine, a If any fuel leakage is detected, repair
check for fuel leakage according to the fol- it and check again from step 2).
lowing procedure. a If no fuel leakage is detected, check
is completed.
46 125E-5 Series
50 Disassembly and assembly SEN00699-03
125E-5 Series 47
SEN00699-03
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10
48
SEN00700-00
125E-5 Series
125E-5 Series 1
SEN00700-00 50 Disassembly and assembly
2 125E-5 Series
50 Disassembly and assembly SEN00700-00
[*4]
3 Joint bolt of pump side:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*5]
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm}
[*6]
2 Mounting bolt: Gasket sealant (LT-2)
125E-5 Series 3
SEN00700-00 50 Disassembly and assembly
4 125E-5 Series
50 Disassembly and assembly SEN00700-00
125E-5 Series 5
SEN00700-00 50 Disassembly and assembly
2) Set the sleeve of the seal to the end of the Front oil seal
crankshaft, and then tighten bolt N3
evenly to press fit sleeve and seal assem- Removal
bly (2) until the end face of tool N2 Remove front oil seal (1).
reaches the end of crankshaft (4). a For the work up to removal of the clamp pulley
(damper), see the Shop manual for the appli-
cable machine.
6 125E-5 Series
50 Disassembly and assembly SEN00700-00
125E-5 Series 7
SEN00700-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
8
SEN05202-00
125E-5 Series
125E-5 Series 1
SEN05202-00 90 Repair and replacement of parts
Flowchart
Repair of cylinder block top and counterbore by grinding
a For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
a If the judgment of No. 9 is NO, examine A.
2 125E-5 Series
90 Repair and replacement of parts SEN05202-00
125E-5 Series 3
SEN05202-00 90 Repair and replacement of parts
4 125E-5 Series
90 Repair and replacement of parts SEN05202-00
Replacement/Rebuilding
Symbol Part No. Part name Q'ty Remarks
item
N 795-931-1100 Seal puller assembly 1
1 795T-421-1340 Sleeve jig 1 For press fitting standard
2 01010-61635 Bolt 3 seal
3 01643-31645 Washer 3 (For wet type)
125E-5 Series 5
SEN05202-00 90 Repair and replacement of parts
6 125E-5 Series
90 Repair and replacement of parts SEN05202-00
Note) We will not be liable for any result of use of special tools manufactured according
to the following drawings.
Q1. Sleeve jig
125E-5 Series 7
SEN05202-00
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
8
SEN05203-01
125E-5 Series
125E-5 Series 1
SEN05203-01 90 Repair and replacement of parts
1. Cylinder head
2. Crosshead guide
3. Valve guide
4. Valve seat insert (exhaust side)
5. Valve (exhaust valve)
6. Valve (intake valve)
7. Valve seat insert (intake side)
2 125E-5 Series
90 Repair and replacement of parts SEN05203-01
125E-5 Series 3
SEN05203-01 90 Repair and replacement of parts
Fig. A Fig. D
a: Sink e: Projection
1. Crosshead guide
Fig. B 2. Cylinder head
Fig. C
d: Projection
4 125E-5 Series
90 Repair and replacement of parts SEN05203-01
125E-5 Series 5
SEN05203-01 90 Repair and replacement of parts
6 125E-5 Series
90 Repair and replacement of parts SEN05203-01
6. Push in 3 claws (10) of puller head (9) of tool D When pulling out valve seat insert (a) by weld-
with the hand and put them in valve seat insert ing a bar to it
(a). 1. Weld bar (b) (Length: 0.1 – 0.5 mm shorter
than valve seat inside diameter, Diameter:
7. Tighten screw (12) to press 3 claws (10) Approx. 10 mm) to the inside of valve seat
against the inside groove of valve seat insert insert (a).
(a). a Take care that welding spatters will not
a If screw (12) is tightened too strongly, the stick to the head.
insert will be broken and become difficult
to pull out. Accordingly, stop tightening 2. After the temperature of the welded parts has
when 3 claws (10) reach the groove fully. decreased to around the ambient temperature,
insert an unnecessary valve (c) in the reverse
8. Put bridge (8) in the outside of puller head (9), direction and hit its head with a small hammer
place plates (11) and (7) on the bridge, and to pull out valve seat insert (a).
tighten nut (6) to pull out valve seat insert (a). a If a large impact is given, the welded parts
may come off. Take care.
125E-5 Series 7
SEN05203-01 90 Repair and replacement of parts
8 125E-5 Series
90 Repair and replacement of parts SEN05203-01
125E-5 Series 9
SEN05203-01 90 Repair and replacement of parts
47.5 +0.100 0
Standard 7.5 –0.1 47.5 +0.020 54.06 ± 0.2 11.38 ± 0.1
+0.090 +0.010
47.75 +0.100 0
0.25 OS 7.5 –0.1 47.75 +0.020 54.31 ± 0.2 11.38 ± 0.1
+0.090 +0.010
48.0 +0.100 0
0.50 OS 7.62 –0.1 48.0 +0.020 54.56 ± 0.2 11.5 ± 0.1
+0.090 +0.010
48.25 +0.100 0
0.75 OS +0.090 7.75 –0.1 48.25 +0.020
+0.010 54.81 ± 0.2 11.63 ± 0.1
48.5 +0.100 0
1.00 OS 7.88 –0.1 48.5 +0.020 55.06 ± 0.2 11.76 ± 0.1
+0.090 +0.010
a OS: Oversize
46.5 +0.080 0
Standard 7.5 –0.1 46.5 +0.020 51.70 ± 0.2 10.7 ± 0.1
+0.070 +0.010
46.75 +0.080 0
0.25 OS 7.5 –0.1 46.75 +0.020 51.95 ± 0.2 10.7 ± 0.1
+0.070 +0.010
47.0 +0.080 0
0.50 OS 7.62 –0.1 47.0 +0.020 52.20 ± 0.2 10.82 ± 0.1
+0.070 +0.010
47.25 +0.080 0
0.75 OS 7.75 –0.1 47.25 +0.020 52.45 ± 0.2 10.95 ± 0.1
+0.070 +0.010
47.5 +0.080 0
1.00 OS 7.88 –0.1 47.5 +0.020 52.70 ± 0.2 11.08 ± 0.1
+0.070 +0.010
a OS: Oversize
10 125E-5 Series
90 Repair and replacement of parts SEN05203-01
125E-5 Series 11
SEN05203-01 90 Repair and replacement of parts
2. Fit the contact surface of the valve seat insert Final inspection
to the valve by using compound. q Thinly apply red lead to the valve seat insert
1) Thinly apply rough compound mixed with contact surface of a new valve and insert that
oil to the seat surface of a valve and insert valve in the valve guide.
that valve in the valve guide. q Lightly press the valve against the valve seat
2) Install the fitting rod to the valve head and insert and rotate it 10°.
lightly hit valve against the valve seat q Check the valve seat insert contact surface of
while rotating it with both hands to fit the the valve and ensure that the contact is even
valve to the valve seat. and is not broken.
3) After the valve and valve seat are fitted q Or, make marks (m) (about 20 places) on the
and their surfaces become smooth, wipe valve seat insert contact surface of a new
off the compound. valve with a pencil and insert that valve in the
4) Apply fine compound and fit the valve and valve guide.
valve seat again similarly to the above q Lightly press the valve against the valve seat
until they are fitted to each other without insert and rotate it 10°.
breakage. q Ensure that all the pencil marks (m) have been
erased evenly.
When master valve is used
12 125E-5 Series
90 Repair and replacement of parts SEN05203-01
125E-5 Series 13
SEN05203-01 90 Repair and replacement of parts
Repair of valve by grinding a Apply dial gauge (1) to the facial runout mea-
suring point of seat contact surface (c) of the
a Valve grinding tool valve and rotate the valve to measure its facial
Symbol Part No. Part name runout while pressing it toward left (d).
Commercially Intake valve: Max. 0.045 mm (TIR)
H Valve refacer
available Exhaust valve: Max. 0.030 mm (TIR)
a TIR is an abbreviation for Total Indicator Read-
Grinding of seat contact surface of valve ing, which is the difference between the maxi-
q Using tool H, grind the seat contact surface of mum and minimum readings in runout
the valve. measurement.
14 125E-5 Series
90 Repair and replacement of parts SEN05203-01
125E-5 Series 15
SEN05203-01
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 10-10
16
SEN05204-00
125E-5 Series
125E-5 Series 1
SEN05204-00 90 Repair and replacement of parts
1. Cylinder liner
2. Clevis seal
3. Cylinder liner O-ring
4. Cylinder block
5. Main bearing metal cap bolt
6. Main bearing metal cap (No. 1, 2, 3, 4, 5 and 6 are same)
7. Camshaft bushing
2 125E-5 Series
90 Repair and replacement of parts SEN05204-00
125E-5 Series 3
SEN05204-00 90 Repair and replacement of parts
Fig. A Fig. D
Fig. B Fig. E
Fig. C Fig. F
4 125E-5 Series
90 Repair and replacement of parts SEN05204-00
Fig. G
i: Upper section
j: Lower section
125E-5 Series 5
SEN05204-00 90 Repair and replacement of parts
1. Crankshaft
2. Main bearing metal (upper)
3. Main bearing metal (lower)
4. Thrust metal (All of upper x 1 and lower x 2 are the same)
6 125E-5 Series
90 Repair and replacement of parts SEN05204-00
125E-5 Series 7
SEN05204-00 90 Repair and replacement of parts
8 125E-5 Series
90 Repair and replacement of parts SEN05204-00
Scuffing on bolt seat surface Scuffing on bolt seat surface Replace bolt
a Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on it.
125E-5 Series 9
SEN05204-00 90 Repair and replacement of parts
Fig. H
a: Measured value
Fig. J
b: Inspection range
c: Streaks
d: Lengthwise direction
10 125E-5 Series
90 Repair and replacement of parts SEN05204-00
5. Using the drive tool, press fit the gear with the
timing mark out until its side contacts the cam-
shaft flange.
a Press fit the gear quickly before it cools
down.
125E-5 Series 11
SEN05204-00 90 Repair and replacement of parts
2nd time 196 {20} 191 – 201 {19.5 – 20.5} Side machining of main bearing metal cap
(Machine only No. 7 main bearing metal cap)
3rd time Tightening by 90° +30°
90° 0 1. Insert cast iron bushing (3) and pass arbor (4)
through it.
3. Set the cylinder block mounting jig on the table
of the horizontal boring machine and install the 2. Install facing tool (5) to the arbor.
cylinder block by fitting its cylinder liner mount-
ing hole to the datum line of the jig. 3. Cut main bearing metal cap (1) to the degree
that facing tool almost touches the cylinder
block surface.
12 125E-5 Series
90 Repair and replacement of parts SEN05204-00
125E-5 Series 13
SEN05204-00 90 Repair and replacement of parts
a Connecting rod small end bushing replace- 2. Install the bushing to push tool (1), set push
ment tool tool (2), and fix them with nut (4).
Symbol Part No. Part name a Match the oil holes of the bushing and
L 795-240-6401 Push tool (KIT) connecting rod to each other.
14 125E-5 Series
90 Repair and replacement of parts SEN05204-00
Replacement of cam bushing 2) While hitting bar (1), drive out the bushing
from the cylinder block.
a Cam bushing replacement tools
Symbol Part No. Part name
M 795-213-1200 Push tool (KIT)
Removal
1. Pulling out of No. 1 and No. 7 bushings
1) Assemble push tool (2), collar (3) and bar
(1) of tool M.
2) While hitting bar (1), drive out the bushing
from the cylinder block.
Installation
a Cam bushing installation drawing
125E-5 Series 15
SEN05204-00 90 Repair and replacement of parts
2. Press fitting of No. 2 and No. 6 bushings 4. Measurement after bushing is press fitted
1) Install bar (1), push tool (2), collar (3) and 1) Using dial inside gauge (a), measure the
guide (4) to the bushing. inside diameter of the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a n d bu s h i n g a r e
matched to each other.
16 125E-5 Series
90 Repair and replacement of parts SEN05204-00
Replacement of engine rear seal 2. Pull slide hammer (1) of the seal puller to pull
out the seal with impacts.
a Engine rear seal replacement tools a Rear seal (c) can be pulled out easily, if it
Symbol Part No. Part name is driven in a little to separate it from the
N 795-931-1100 Seal puller assembly flywheel housing in advance.
a Do not damage the crankshaft.
a For disassembly and assembly of flywheel and a Do not use a drill since chips will enter the
flywheel housing, see "Disassembly and engine.
assembly".
125E-5 Series 17
SEN05204-00 90 Repair and replacement of parts
2. Screw drill end (6) into the metal ring of rear a Before installing the rear seal, remove all
seal (c) and pull slide hammer (1) of the seal flaws, sharp edges, burrs, rust, etc. from the
puller to pull out the seal with impacts. end corners and sliding surfaces of the crank-
a Rear seal (c) can be pulled out easily, if it shaft and from the flywheel housing.
is driven in a little to separate it from the a Do not apply oil or grease to the sliding sur-
flywheel housing in advance. faces of the crankshaft and lip (e) of the rear
a Do not damage the crankshaft. seal.
a Do not use a drill since chips will enter the Wipe off the oil from the sliding surfaces of the
engine. crankshaft thoroughly.
18 125E-5 Series
90 Repair and replacement of parts SEN05204-00
4. Install sleeve jig (1) and clamp bolts (2) (Stem Installation of rear seal (with sleeve)
length: 35 mm). a Handle the spare rear seal and sleeve (n) as
a Do not install washers to the bolts. an assembly and do not separate them.
125E-5 Series 19
SEN05204-00 90 Repair and replacement of parts
2. Install sleeve jig (4), clamp bolts (5) (Stem 5. Remove clamp bolts (8) (Stem length: 45 mm
length: 50 mm), and 1 washer (6). (wet), 40 mm (dry)), install 3 washers (9) each,
and tighten bolts (8) evenly again to press fit
3. Evenly tighten clamp bolts (5) to press fit the the rear seal until end (q) of sleeve jig (7)
rear seal until they stop. touches end (r) of the crankshaft.
a Be sure to press fit rear seal (c) and a After press fitting, remove the gasket seal-
sleeve (n) as an assembly. ant projected around the periphery.
20 125E-5 Series
90 Repair and replacement of parts SEN05204-00
125E-5 Series 21
SEN05204-00 90 Repair and replacement of parts
Repair of crankshaft by grinding q Finish the main journal and pin journal accord-
ing to the following procedure.
q When the crankshaft is worn, seized or dam-
aged slightly and needs to be repaired, grind it Main journal oil hole (See figure below)
to one of the following undersizes. q Dimension of tapered part (a) of oil hole:
Undersizes: 0.25, 0.50, 0.75, 1.00 mm 12 mm
q If the crankshaft is bent or worn unevenly, it q Angle (b) of tapered part of oil hole: 120°
should not be repaired but should be replaced. q Surface roughness of oil hole top (c):
(Repairing the crankshaft requires high tech- 1.6S (Finished with sandpaper)
nologies) q Dimension of parts (R) at 2 places: 1 – 2 mm
q Do not straighten the crankshaft with a press
since it bends again while the engine is oper-
ated.
q Do not repair the journal portions by build-up
welding or plating since they have been
treated by induction hardening etc.
q If the crankshaft is worn unevenly, discard it
since it may be bent and/or unbalanced even
after it is repaired.
q Measure the portions to be ground and then
decide the undersize dimension.
q Judging from the measured value, if wear of
the crankshaft exceeds the using limit after
grinding to the undersize, discard the crank-
shaft.
q Limit application of repair by plating to the fol- Pin journal oil hole (See figure below)
lowing portions. q Finish part (d) with sandpaper.
q Rear seal journal portion q Check part (e) extremely carefully since
q Crank gear mounting portion quenching crack tends to occur in that part.
q Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.
22 125E-5 Series
90 Repair and replacement of parts SEN05204-00
Equipment necessary for grinding Check during and after repair by grinding
q Magnaflux inspection machine
q Shore hardness tester Check of fillet (R) portion
q Etching kit q Check that each fillet (R) portion is connected
q Crankshaft grinding machine to the journal shoulder smoothly.
q Crankshaft polishing machine q Ensure that there is not a scratch or a seized
q Surface roughness gauge part in the fillet (R) portion at which stress will
q Fillet (R) gauge be concentrated.
q Ensure that the (R) dimension of the fillet is
Inspection before repair by grinding within the standard dimension.
(R) dimension:
Visual check Must be between the minimum radius gauge
q If there is a visible thermal crack on the crank- and maximum radius gauge.
shaft, discard the crankshaft since its hard-
ened layer is damaged.
q If the journal surface of the crankshaft or a
shoulder portion near the thrust face which has
not been machined are discolored, discard the
crankshaft since its temperature has increased
high.
q If wear and/or damage of the journal surface of
the crankshaft cannot be removed by grinding
to the undersize, discard the crankshaft. (High
skill is required)
q If a round portion etc. of the crankshaft which
affects strength is damaged, discard the crank-
shaft.
q If only either side of the crankpin journal of the
crankshaft is worn, discard the crankshaft
since such wear affects balance.
125E-5 Series 23
SEN05204-00 90 Repair and replacement of parts
q Using a fillet gauge and a penlight, check the Check for seizure mark by etching
(R) dimension and rise of the fillet according to q After repairing by grinding, check that there is
the following procedure. no grinding burn mark by etching inspection.
q If the journal portion is damaged, seized or
1. While moving the minimum radius gauge from streaked in a bearing accident etc., check for a
the journal surface to the fillet portion, through seizure mark by etching and use the result for
light from the rear of the ball to check contact judgment of hardness reduction and decision
point (a). of an undersize dimension.
q If the fillet is normal, only 1 contact point
q The purpose of etching inspection is to check
(b) moves around the periphery of the ball
for a seizure mark that cannot be detected by
which the ball is moving.
visual inspection or hardness test and a grind-
q If 2 contact points are seen at any place
ing burn mark caused by heating during grind-
while the ball is moving, a part of the fillet
ing.
radius is smaller than the minimum value.
In this case, repair again. q Seizure and grinding burn at the journal or fillet
portion are breakage of the metallic organiza-
tion. Although they occur in a shallow part,
they can cause stress concentration that can
break the crankshaft.
24 125E-5 Series
90 Repair and replacement of parts SEN05204-00
7. After finishing inspection, polish out the sur- 1. Measurement of overall length alignment
face discolored by etching and then clean and q Support the front and rear of the crank-
dry. shaft and measure the runout of the cen-
Neutralize the inspected surface by cleaning it ter main journal with a dial gauge.
with weak solution of calcium hydroxide or
equivalent alkaline solution.
Magnaflux inspection
q Before using the repaired crankshaft, check it 2. Measurement of adjacent alignment
by magnaflux inspection to ensure that it has q Support the journal adjacent to the journal
no crack. to be measured and the rear end journal
q Extremely closely check the journal fillet por- and measure the runout of the measured
tion which is in the dangerous area of each journal with a dial gauge.
web of the crankshaft.
q This part must not have even a slight crack 3. Measurement of crankshaft front end align-
since it receives the largest stress on the ment
crankshaft. q Support the front and rear end journals of
the crankshaft and measure the runout at
a part within 6 mm from the crankshaft
front end.
125E-5 Series 25
SEN05204-00 90 Repair and replacement of parts
26 125E-5 Series
90 Repair and replacement of parts SEN05204-00
125E-5 Series 27
SEN05204-00 90 Repair and replacement of parts
q Adjust the grinding stone edge to the arc of the q Set the standard peripheral speed of the grind-
fillet with the grinding stone modifying device. ing stone to 2,000 m/min when the crankshaft
rotation speed is about 50 rpm.
Finishing of surface
q Finish the journal surface smoothly since it
affects the fatigue strength of the crankshaft
and wear of the bearing.
q Surface roughness standard after grinding
Journal surface, thrust surface and fillet por-
tion: Max. 0.8S
Pin and main boss portions: Max. 3.2S
End nose portion and rear flange surface:
Max. 2.0S
q When using a belt-type polishing machine, pull
the sandcloth in the rotation direction of the
q First, repair the flat face of the grinding stone crankshaft.
and record the reading of the feed dial gauge. This must be observed to scatter the fine parti-
Next, bring the radius of either edge arc in con- cles and prevent scratches caused by those
tact with the flat face of the grinding stone. particles rolled in.
q Limit the final feed rate for the repaired face to q Finish the areas around oil holes to the same
0.013 mm. surface roughness of the journal portion.
q Hold a small rough grinding stone with the q Polish finishing margin: 0.007 – 0.008 mm
hand, apply it to the front face of the repaired q Remove all rust and corrosion which can wear
grinding stone, and grind lightly so that the the bearing and then apply high quality rust
edge arc will be smoothly in contact with the preventive oil.
front face of the grinding stone. q Finishing condition (Reference)
At this time, slightly slant the grinding stone in Sandpaper: AA#120
your hand and lightly press it against the Shaft rotation speed: 100 rpm
repaired grinding stone. Grinding speed: 36 m/min
q While grinding a piece of wood on trial and
checking the (R) dimension and rise of the fillet Work after repair by grinding
with the gauges, repair the grinding stone so q Ensure again that each dimension is as speci-
that a complete shape of the fillet can be fied.
obtained. q Thoroughly clean each part, particularly the oil
q Similarly, repair the edge on the opposite side holes, and then apply high quality rust preven-
of the grinding stone. tive oil all over the crankshaft.
q Finally, grind the crankshaft on trial and check q Handle the crankshaft with extreme care not to
the shape of the fillet. scratch or damage it.
q When storing the crankshaft for a long period,
Prevention of grinding burn support it on 3 points or keep it erected with a
q Observe the following precautions to prevent sling so that it will not bend.
grinding burn.
q Apply the flange grinding method where the
grinding stone is applied perpendicularly to the
crankshaft.
The bump grinding method, where the grinding
stone is applied to the crankshaft and moved
crosswise, can cause grinding burn.
q Use all the width of the grinding stone and
avoid grinding the boss surface.
Finish the boss surface by polishing.
When feeding the grinding stone against the
boss surface, limit the feed rate to 0.025 mm/
sec.
q Start feeding cooling oil to the side profile
machine and main jet before starting grinding
and supply it to the ground portion sufficiently.
28 125E-5 Series
90 Repair and replacement of parts SEN05204-00
125E-5 Series 29
SEN05204-00
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
30